lead free piezoceramicactuator development...summary • future ... undergraduate & msc project...

Department of Engineering & MathematicsSheffield Hallam University

Pond Street, Sheffield. S1 1WB.

LeadFreePiezoceramic ActuatorDevelopmentAirbusDiPaRT 2017AnnualMeeting,CRMS,Bristol

Dr.JonnyPottsSeniorLecturer:Aerodynamics

Sheaf4205,Ext.6450,[email protected]

Dr.AntonioFeteira, Reader:Materials



Presenter Biog

Dr Jonny Potts is a Senior Lecturer in Aerospace Engineering at Sheffield Hallam University. Hehas around 15 years’ experience in research and development within a University context,working directly with industrial partners (BAE Systems, Airbus, EDF Energy), many of theseresearch programmes have been focussed on flow control methodologies. He devised andconducted a set of experiments to demonstrate micro-fabricated hot film sensors and pulsedactuator technologies in transonic flow as part of the Integrated Wing (DTI) programme. Hedesigned and fabricated a cassette of SJA actuators for large scale wind tunnel test under theClean Sky VELOCIRAPTOR project. He delivered the final demonstration phase of the 5 yearFLAVIIR programme (BAE Systems, EPSRC) comprising in-flight testing of novel circulationcontrol devices and fluidic thrust vectoring methodologies for UAV applications. More recently,he has been working with the materials science group towards a high strain lead freepiezoceramic alternative specifically for aerospace actuator technology applications. Alongsidethe materials science he has been developing a test-bed capability for aero-mechanical testingof actuator performance. This includes the development of a closed return low speed windtunnel facility, which is due for commissioning by Q2 2018.



Abstract

EU legislation currently ring fences lead (Pb) piezoceramic materials. To mitigate anyforthcoming requirement for lead free piezoceramics by law, the present research seeks tobring alternative materials towards consideration for end use applications within an industrialcontext. The group looks to establish a test bed for aero-mechanical testing of state of the artpiezoceramic compounds coming straight out of the materials lab (or from industry) todemonstrate the aero-mechanical performance of flow control actuator devices utilising leadfree piezoceramics. Our work on lead free piezoceramic material characterisation is wellestablished, BNT materials are performing well in comparison to their lead based equivalentsPZT, particularly to high temperatures with at least analogous peak strain properties. Shortterm proposed work is to utilise a tape caster to fabricate thin piezoceramic layers then bondto a circular brass shim to construct a simple actuator diaphragm from entirely lead freematerials, then characterise aero-mechanical performance of a synthetic jet actuator utilisinghot wire and laser vibrometer measurements across a frequency and peak to peak voltagerange. Utilising the synthetic jet as a baseline actuator, alternative piezoceramic actuatordevices with different piezoceramic form factors will be considered to maximise the outputperformance for flow control applications or otherwise.



Summary

• FutureRequirementforLeadFreePiezoceramics– LegislativeexemptionssurroundelectronicPZTapplications

• Establishtest-bedforactuatorsdrivenbynewmaterials– Materialproperties(peakstrain)– Aero-mechanicalperformance(fluidicoutputvelocity)

• BaselineActuatorFabrication(SyntheticJet)– Piezoceramic bondedtobrassshimpluselectrodelayer



PreviousWorkinFlowControl:IntegratedWing– TransonicActiveFCDemonstrations

• MEMS Hot Film Sensors



• MEMS beam actuator valve (non-zero net mass flow)




• MEMS beam valve actuator (non-zero net mass flow)




SyntheticJetActuator(SJA)Design– AdditiveLayerManufacturing (ALM)PreviousWork:CleanSky – Velociraptor



SyntheticJetActuatorArray– ConceptualDesign

PreviousWork:CleanSky – Velociraptor



PreviousWork:CleanSky – VelociraptorSyntheticJetActuatorArray– SJACassetteincl.HealthMonitoring Sensors



Attended materials seminar reporting strain variation properties of different piezoceramics

Realisation that prior art PZT diaphragm based actuators could be replaced with new materials

Undergraduate & MSc project work to initiate further materials research activities and aero-mechanical testing

Full testing capability recently assembled to conduct materials testing through actuator fabrication and aero-mechanical performance testing

Lightbulbmoment



What happens when you squeeze a lead free orange?

MaterialsBackground



What happens when you squeeze a lead free piezoelectric?

D=ds[C/m2]

MaterialsBackground



Piezoelectric Effects

Dielectric

Input

Output +

-

Force

InputOutput

Dielectric

•Directeffect

•Converseeffect

D=ds[C/m2] Applications:PressuresensorsUltrasonicimaging

Applications:ActuatorsMotors

S=dE

MaterialsBackground



Ec +E-E

PrP V=0

V=0

Virgincurve

Electromechanical response of ferroelectrics

MaterialsBackground



Commercial Piezoelectrics are based onPbZrO3-PbTiO3 (PZT) ceramics

MaterialsBackground



Why do we need Pb-free piezoelectrics?

EnvironmentalandhealthissuesrelatedtoPb-basedmaterialsarewellknown.

RestrictionofHazardousSubstancesDirectiveAccording to RoHS, any homogeneous component containing more than0.1% weight of lead is subjected to restrictions; and hence, the fact that thebest piezoelectric materials contain lead up to 60% weight, may in the future,seriously hamper their use in everyday applications.

Legislation



Material properties test equipment well established within Materials & Engineering Research Institute (MERI) at SHU

• aixACT TF1000Analyserferroelectrictestingchamber(middle)• aixACT aixPES terminal:ferroelectrictestingsoftware

EstablishingTest-BedCapability:FerroelectricTesting



Standard material sample fabrication process• Mixpowdercompound• Presspellet• Furnace• Grind

EstablishingTest-Bed:Piezoceramic FabricationProcess



Proposed material sample fabrication process• Mixpowdercompound• Formulateslurry• Tapecast• Furnace

EstablishingTest-Bed:Piezoceramic FabricationProcess



EstablishingTest-Bed:DiaphragmFabricationCircular diaphragm punch tool



EstablishingTest-Bed:Aero-electro-mechanicalTestingTrek PZD700A HVPA, TSI IFA-300 HWA, Polytec CLV-2534 Laser Vibrometer



EstablishingTest-Bed:SHULowSpeedWindTunnel• Small scale wind tunnel 0.45x0.45x1.3m, 50m/s.

• Wind tunnel due for commissioning 2018, Rolling Road 2020



MaterialResults– BNTFamily:BiNaTiO3-TiO3• BNT-Sr-Mn Bismuth Sodium Strontium Titanatewith Manganese doping

-40

-30

-20

-10

0

10

20

-80 -60 -40 -20 0 20 40 60 80

Pola

risat

ion

(uC

/cm

^2

Field (kV/cm)

BNT-25%Sr-2%MnA Plot of Polarisation against Field

40kV

45kV

50kV

55kV

60kV

65kV



TypicalResultsfromSJATesting(UoM)

(Gomes&Crowther,2006)



Material properties testing of lead free piezoceramics well established at SHU MERI

BNT family showing promising performance for driving actuators

Lead free SJA for flow control applications currently at tape caster trialling stage

Test-bed undergoing set-up towards demonstrating characterisation of COTS diaphragm SJA ahead of lead free prototypes becoming available

Conclusions



END

lead free piezoceramicactuator development...summary • future ... undergraduate & msc project...

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