etrema presentation mrs 2011
DESCRIPTION
Presentation given at a local MRS Chapter meeting on Rare Earth Technology; April 2011.TRANSCRIPT
ETREMA Products, Inc.
Giant Magnetostrictive Material Technologies
Symposium on Rare Earth MaterialsIowa State University
Eric Summers, ETREMA Products
April 7, 2011Symposium on Rare Earth Materials
Iowa State University
ETREMA Products, Inc.Outline
Intro to ETREMA ProductsTerfenol-D TechnologyTerfenol-D ApplicationsImpact of Rare Earth Environment on T-DGalfenol Technology – non REE SubstitutePermanent MagnetsSummary & Conclusions
April 7, 2011Symposium on Rare Earth Materials
Iowa State University
ETREMA Products, Inc.ETREMA Products, Inc.
Primary business: smart material sales, smart smart material sales, smart material enabled devices, and engineering services material enabled devices, and engineering services
based on magnetostrictionbased on magnetostriction
• Small business – Ames, IA• Started in 1987 as a foundry for
Terfenol-D• Developed engineering capability
in early 90’s to grow the market• World leader in products and
systems based on magnetostrictive technology
April 7, 2011Symposium on Rare Earth Materials
Iowa State University
ETREMA Products, Inc.
Products & ApplicationsLow frequency
applications(DC – 200 Hz)
Mid frequency applications
(200 Hz – 10 kHz)
High frequency applications
(10 kHz – 30 kHz)
Standard actuator line Ultrasonic CU18
AMS activemachining
systems
Integrated systems (transducer, amplifier,
radio)
SONAR transducers
Oil & Gas Tools
April 7, 2011Symposium on Rare Earth Materials
Iowa State University
ETREMA Products, Inc.
Magnetostriction• Magnetostriction converts electrical energy into mechanical
energy and vice versa• Anisotropic property – crystal orientation dependence• Change in shape is completely elastic - no fatigue
Magnetic
Field
Mechanical
Strain
Actuator -
Joule Effect
Sensor –
Villari Effect“energy harvesting”
Magnetostriction is a reversible effect
April 7, 2011Symposium on Rare Earth Materials
Iowa State University
ETREMA Products, Inc.
Giant Magnetostriction
Discovered in the 1960’s for heavy rare earth metals – Legvold, Clark, and Rhyne
At cryo temps or lower, ~1% strain, Tb & Dy
1970’s search for room temperature giant magnetostrictive alloys
RE-Ni, RE-Co, RE-Fe alloys investigated
TbFe2 and SmFe2; (+2000 ppm, -2000 ppm at RT)Magnetic anisotropy still very large
Work completed at Ames Lab and Naval Ordnance Labs (NOL)
April 7, 2011Symposium on Rare Earth Materials
Iowa State University
ETREMA Products, Inc.Terfenol-D
Terfenol-D is an intermetallic compound:Terbium TbDysprosium DyIron Fe
Nominal composition is Tb0.3Dy0.7Fe1.92Tb:Dy ratio tailored to fit application
Tb generates the majority of the magnetostrictionDy reduces magnetic anisotropyFe stabilizes magnetic ordering to ambient temperatures (raises Tc)
April 7, 2011Symposium on Rare Earth Materials
Iowa State University
ETREMA Products, Inc.
Terfenol-D Microstructure
Eutectic
RFe2
• R (Tb, Dy) Fe2
dendrites aligned parallel
•
Eutectic phase (Tb, Dy) sets spacing between dendrites
Fe2
Dy
Fe3
Dy
Dy
–
Fe Phase Diagram
April 7, 2011Symposium on Rare Earth Materials
Iowa State University
ETREMA Products, Inc.
•
Excessive (Tb, Dy) losses can lead to RFe3
phase and/or Widmanstatten precipitates
•
Symmetry disruption and domain wall pinning
April 7, 2011Symposium on Rare Earth Materials
Iowa State University
ETREMA Products, Inc.Terfenol-D Mfg. Techniques
Method Advantage DisadvantageBridgman (ECG)
Production method
Smallest diameter -
10mmLow cost, Diameters upto 65mm diameter
FSZM
Highest strain
Largest diameter -
9mmFull <112> orientation
Research methodHighest Cost
Powder Metallurgy
Near Net Shape
Performance issuesProduction method for
small pieces
Terfenol-D ECG located at ETREMA
April 7, 2011Symposium on Rare Earth Materials
Iowa State University
ETREMA Products, Inc.
0
200
400
600
800
1000
1200
1400
1600
-2000 -1500 -1000 -500 0 500 1000 1500 2000
Applied Field (Oe)
Mag
neto
stric
tion
(ppm
)
FSZMECG
Magnetostriction in Terfenol-D
April 7, 2011Symposium on Rare Earth Materials
Iowa State University
ETREMA Products, Inc.AMS Technology
Enables production of tight tolerance, non-round components • Target market – small engine
pistons• Readily adapted to standard
CNC lathes• Spindle speed up to 6000
RPM• 1 piston every 10 seconds• Multiple systems in
production – first system online in 2001
AMS actuator integrated onto a conventional lathe
April 7, 2011Symposium on Rare Earth Materials
Iowa State University
ETREMA Products, Inc.Actuator Video
April 7, 2011Symposium on Rare Earth Materials
Iowa State University
ETREMA Products, Inc.AMS Details
AMS is a T-D actuator working in a micro-positioning applicationRobust nature, positioning speed (bandwidth), and accuracy (repeatability) are what make AMS unique.
We move the actuator 5000 times every second and hold it to within 1 micron of desired position. Compensating for the natural ferromagnetic hysteresis in the T-D was the major technological leap that occurred during AMS development.
April 7, 2011Symposium on Rare Earth Materials
Iowa State University
ETREMA Products, Inc.
CU18A Ultrasonic Actuator15-20 kHz horn bandwidthMaximum output power at 18 kHzPeak output displacement = 10 micronsHigh dynamic force = 3250 NMagnetic flux leakage free
• Dimensions: 2” dia. X 5.2” length
• Multiple mounting options and horn configurations
• Active cooling option
• www.etrema.com
April 7, 2011Symposium on Rare Earth Materials
Iowa State University
ETREMA Products, Inc.
CU18A + Horn
ApplicationsUltrasonic sourceMicro positioningSono-Chemistry
CU18 with 20.5 kHz horn attached
April 7, 2011Symposium on Rare Earth Materials
Iowa State University
ETREMA Products, Inc.Sono-Chemistry
High intensity acoustic fields create cavitationCavitation bubbles are essentially micro scale combustion chambers reaching temperatures of 9,000 °FExtremely high mechanical forces:
15,000 psi250 mph jet streams
Particle dispersion, emulsification, degassing
Photos by K.S. Suslick, University of Illinois.
April 7, 2011Symposium on Rare Earth Materials
Iowa State University
ETREMA Products, Inc.Cavitation
April 7, 2011Symposium on Rare Earth Materials
Iowa State University
ETREMA Products, Inc.Navy Sonar Transducers
• Terfenol-D was invented by the U.S. Navy for its next generation sonar systems
• SEA TALON is a program with Lockheed-Martin for an active source towed by an unmanned underwater vehicle
• Multiple other programs• Either performance data is
classified, designs are proprietary, or NDA’s exist between parties
Sea Talon Program
April 7, 2011Symposium on Rare Earth Materials
Iowa State University
ETREMA Products, Inc.
Small Synthetic Aperture Sonar*
Work done out of NSWC – Panama City with Penn State ARL and Woods Hole Oceanographic Inst.
Terfenol-D is utilized as one of the active sourcesHigh resolution imagery at low frequencies – Small Synthetic Aperture Minehunter (SSAM)SSAM is a dual frequency band system; high and low frequency bands
Imaging resolutions at high frequency: 1 in x 1 inImaging resolutions at low frequency: 3 in x 3 in
Detect and classify proud and shallow buried targets located on ocean floor
* Daniel Brown, Daniel Cook, Jose Fernandez, Naval Surface Warfare Center -
Panama City, Code HS11, 110 Vernon Avenue, Panama City, FL 32407-7001* Proceedings of the MTS/IEEE OCEANS 2006 Boston Conference and Exhibition
April 7, 2011Symposium on Rare Earth Materials
Iowa State University
ETREMA Products, Inc.
-
Image taken from Woods Hole Oceanographic Institute website
SSAM on REMUS 600 AUV
April 7, 2011Symposium on Rare Earth Materials
Iowa State University
ETREMA Products, Inc.
-
Image taken from Woods Hole Oceanographic Institute website
-
Image taken from Proceedings of the MTS/IEEE OCEANS 2006 Boston Conference and Exhibition
April 7, 2011Symposium on Rare Earth Materials
Iowa State University
ETREMA Products, Inc.
Impact of Current Rare Earth Environment on Applications
Terfenol-D is an alloy of Heavy Rare Earth Elements (HREE’s)
60% Terbium (Tb) and Dysprosium (Dy) by weightHigh purity metals required
Sublimed quality Tb and Dy not distilledTb and Dy sublimed metal supply currently available
High value product for Chinese marketPricing increased dramatically over last 1-2 yearsIncreases impacting at alloy level not yet significant at device or system level Alternative sources and substitutes under investigation
April 7, 2011Symposium on Rare Earth Materials
Iowa State University
ETREMA Products, Inc.
Galfenol a REE Technology Substitute
Low MagnetostrictionStructural (strong)
High MagnetostrictionBrittle
Ni: 50 ppm Terfenol-D: 1000 ppm
Fe-Ga: 200 – 400 ppm, structural
• Discovered in 1999-2000 by: Clark et al., NSWC, Ames Lab (Lograsso et. al)
April 7, 2011Symposium on Rare Earth Materials
Iowa State University
ETREMA Products, Inc.Projected Supply Risk
Supply of Terbium and Dysprosium potentially a problem in the foreseeable futureGallium does not have the same supply risk
Figures copied from US Dept. of Energy, “Critical Materials StraFigures copied from US Dept. of Energy, “Critical Materials Strategy tegy –– December 2010”, p. 8December 2010”, p. 8
April 7, 2011Symposium on Rare Earth Materials
Iowa State University
ETREMA Products, Inc.
Magnetostriction vs. Composition (single crystal)
Fe1-x
Ga(0.15 ≤
x ≤
0.20)
•
All single crystal data taken from Magnetic Materials Group –
Carderock Division, Naval Surface Warfare Center (NSWC)
•
Etrema’s efforts have focused on the first magnetostrictive peak between 15 at% Ga and 20 at% Ga
•
Nominal Ga content in Etrema produced Galfenol is 18.4 at%
•
Etrema produces polycrystalline samples
0 5 10 15 20 25 30 35 40
0
50
100
150
200
250
300
350
400
450
3/2λ 1
00(x
10-6
)
x
Furnace CooledQuenchedDirectionally Solidified (Unannealed)Quenched in BrineFurnace Cooled, Multi-phase
Fe100-xGax
H = 15 kOe
April 7, 2011Symposium on Rare Earth Materials
Iowa State University
ETREMA Products, Inc.
Galfenol vs. Terfenol-D
0
200
400
600
800
1000
1200
0 200 400 600 800 1000Magnetic Field, Oe
Mag
neto
stric
tive
Res
pons
e, p
pm
Galfenol - 18.4R - 7ksi
FSZM T-D - 2ksi
Galfenol –
Terfenol-D Comparison
April 7, 2011Symposium on Rare Earth Materials
Iowa State University
ETREMA Products, Inc.
Galfenol vs Terfenol-D
0
2000
4000
6000
8000
10000
12000
14000
16000
0 200 400 600 800 1000 1200 1400 1600 1800 2000Magnetic Field, Oe
Mag
netic
Flu
x D
ensi
ty, B
, Gau
ss
Galfenol, FSZM18.4-R, 5ksi
Terfenol-D, FSZM, 1ksi
Galfenol –
Terfenol-D Comparison
April 7, 2011Symposium on Rare Earth Materials
Iowa State University
ETREMA Products, Inc.
Galfenol Processing Methods
Oriented Sheet
10 inches
RD(110)<100>
2.5 inches
Oriented Sheet
10 inches
RD(110)<100>RD(110)<100>
2.5 inches
Galfenol nano-wires produced by Dr. Beth Stadler’s
group, U. of Minnesota
April 7, 2011Symposium on Rare Earth Materials
Iowa State University
ETREMA Products, Inc.
Galfenol Components
Laminated and machined threads
Forged and machined shapes
Laminated and milled stack
April 7, 2011Symposium on Rare Earth Materials
Iowa State University
ETREMA Products, Inc.
Galfenol for Micro Devices
Images and video courtesy of Dr. Toshiyuki Ueno, Kanazawa U., JapanGalfenol produced by ETREMA Illustrates Galfenol micro-components can be fabricated using conventional machining techniques
Micro-milling of Galfenol laminate
April 7, 2011Symposium on Rare Earth Materials
Iowa State University
ETREMA Products, Inc.Micro Spherical Motor
Device courtesy of Dr. Ueno, Kanazawa U.Galfenol supplied by ETREMAMulti-DOF in 1 motor
• 1 kHz, 0.2 A
• Angel range = 360°
• Angle velocity = 50°/sec
April 7, 2011Symposium on Rare Earth Materials
Iowa State University
ETREMA Products, Inc.
Role of Permanent Magnets in Magnetostrictive Technologies
Magnetic biasing via PM’s: NdFeB or SmCo used, high strength (grade 38+ for Neo’s, typical)Necessary to prevent frequency doubling and operate in a “linear” regionDC biasing effective but inefficientStable supply of PM’s critical for future magnetostrictive technologies (Terfenol-D or Galfenol)
Optimum bias point for a piece of Galfenol
April 7, 2011Symposium on Rare Earth Materials
Iowa State University
ETREMA Products, Inc.Summary & Future Direction
Terfenol-D is a mature technology integrated into multiple fields-of-useApplications development is dynamicHigh HREE content poses short- and mid-term risksGalfenol is a non-REE substitute under developmentGalfenol technology is transitioning into the Applications stage