Page 15 - ASME SMASIS 2016 Program

Symposia

SYMPOSIUM 4 tests, full scale demonstrations, and application development. Most
recently he was the Principle Investigator for the development and FAA
funded flight test of the SMA actuated wing secondary control surface,
FLIGHT TEST OF A SHAPE MEMORY ALLOY ACTUATED ADAPTIVE Adaptive Trailing Edge system. He received his PhD in Engineering
TRAILING EDGE FLAP Mechanics from Iowa State University 1997 and his BA in Astrophysics
from Princeton 1988. He is a certified TRIZ (Theory of Inventive Problem
Solving) practitioner. He is also a Colonel in the Washington Army National
Frederick Calkins Guard, serving as the Commander of the 205th Regimental Training
Boeing
Institute.

ENGINEERING DESIGN TOOLS FOR SHAPE MEMORY ALLOY
ACTUATORS: CASMART COLLABORATIVE BEST PRACTICES AND
CASE STUDIES
Abstract
Recent advances in SMA actuation and a detailed understanding of wing
design were combined to design, build, and safely demonstrate small Robert Wheeler
trailing edge flaps driven by SMA actuation. As part of a 2012 full-scale Texas A&M University
flight test program a lightweight and compact Shape Memory Alloy (SMA) College Station, TX
rotary actuator was integrated into the hinge line of a small flap on the
trailing edge of a 737-800 wing. Aerodynamic studies of these small
trailing edge flaps show that improved performance requires multiple flap
configurations that vary with flight regime. Configurations include small
angles of deployment for reduced fuel burn and emissions during high Abstract
speed cruise and larger angles of deployment for increased lift and lower The primary goal of the Consortium for the Advancement of Shape
noise during takeoff and approach. SMA actuation is an ideal compact Memory Alloy Research and Technology (CASMART) is to enable the
solution to position these small flaps and increase aircraft performance by design of revolutionary applications based on shape memory alloy (SMA)
simply and efficiently altering the wings aerodynamic characteristics for technology. In order to help realize this goal and reduce the development
each flight segment. Closed loop control of the flap’s position, using the time and required experience for the fabrication of SMA actuation
SMA actuator, was demonstrated at multiple flight conditions during flight systems, several modeling tools have been developed for common
tests. The first part of this paper will cover the design, build, and test of the actuator types and are discussed herein along with case studies, which
SMA components used in the flight actuator system, including qualification highlight the capabilities and limitations of these tools. Due to their ability
of the SMA components for flight testing. The design and performance to sustain high stresses and recover large deformations, SMAs have many
objectives will be summarized. Data from previous extensive testing of potential applications as reliable, lightweight, solid-state actuators. Their
NiTinol rotary actuators, that form the basis for the design of the flight advantage over classical actuators can also be further improved when the
actuators, will be reviewed. Laboratory tests of the flight design will be actuator geometry is modified to fit the specific application. In this paper,
compared to performance predictions. Aircraft integration, the test three common actuator designs are studied: wires, which are lightweight,
methods used to approve the SMA components for integration and flight, low-profile, and easily implemented; springs, which offer actuation strokes
and the test results will be presented. Issues related to the certification of upwards of 200% at reduced mechanical loads; and torque tubes, which
SMA actuators for aerospace applications will be discussed. The second can provide large actuation forces in small volumes and develop a
part of this paper includes an overview of the Adaptive Trailing Edge (ATE) repeatable zero-load actuation response (known as the two-way shape
flight test program including technology development, airplane integra- memory effect). The modeling frameworks, which have been implement-
tion, and full-scale flight testing will be described. The ATE flight test ed in the design tools, are developed for each of these frequently used
program was part of a Boeing and FAA collaboration. Results of the SMA actuator types. In order to demonstrate the versatility and flexibility
successful flight test on a commercial narrow body airplane and the of the presented design tools, as well as validate their modeling frame-
significantly improved performance benefits will be presented. This is the work, several design challenges were completed. These case studies
first flight test of an SMA rotary actuator system, which was matured from include the design and development of an active hinge for the deploy-
TRL 4 to TRL 7 during the program.
ment of a solar array or foldable space structure, an adaptive solar array
deployment and positioning system, a passive air temperature controller
for the regulation of flow temperatures inside of a jet engine, and a
Biography redesign of the Corvette active hatch, which allows for pressure equaliza-
F. Tad Calkins is an Associate Technical Fellow in Boeing Research & tion of the car interior. For each of the presented case studies, a
Technology focused on smart materials, adaptive structures, and active prototype or proof-of-concept was fabricated and the experimental results
flow control technology for both military and commercial aircraft applica- and lessons learned are discussed. This analysis presents a collection of
tions. His research has recently focused on the development of Shape CASMART collaborative best practices in order to allow readers to utilize 15
Memory Alloy (SMA) actuators and supporting technology that provide the available design tools and understand their modeling principles.
new capability to commercial aircraft. This work includes numerous flight These design tools, which are based on engineering models, can provide