Abstract:
A method and sensor for detecting strain using shape memory alloys is disclosed. The sensor comprises a substrate material, a flexible diaphragm provided on the substrate material and a thin film SMA material deposited on the flexible diaphragm. The thin film SMA material is capable of undergoing a phase transformation in response to a physical stimulus being applied thereto. During such a phase transformation, a change occurs in the electrical resistance of the thin film SMA material. By measuring the value of the electrical resistance of the thin film SMA material immediately before and after the thin film SMA material undergoes a phase transformation, the difference in the value of the electrical resistance can be determined and utilized to determine the magnitude of the physical stimulus that was applied to the thin film SMA material causing it to undergo a phase transformation.

Description:
TECHNICAL FIELD  
         [0001]    The present invention relates, in general, to shape memory alloys (SMA&#39;s) and, more particularly, to SMA materials that can be used in sensors to detect strain.  
         BACKGROUND ART  
         [0002]    Shape memory alloys (SMA&#39;s) are a unique class of materials that have the ability to form two different crystalline phases, usually referred to as the martensite and austenite phases, in response to temperature and strain. SMA&#39;s are produced by combining at least two component elements into a desired shape which is then annealed. Immediately upon being annealed, the SMA material is in the austenite phase, having a specific shape (referred to hereinafter as the parent shape), and characterized by a low ductility, high Young&#39;s Modulus and high yield stress. Upon cooling, the SMA material changes into the martensite phase characterized by a high ductility, low Young&#39;s Modulus and low yield stress. In the martensite phase, the SMA material is easily deformed and can take on a different shape from its austenite, or parent, shape by the application of an external strain thereto. The SMA material will retain this different shape until it is heated to its austenite phase transformation temperature. When such heating occurs, the SMA material undergoes a phase transformation to its austenite phase and is transformed back to its parent shape. During this phase transformation the SMA material produces a very high kinetic energy output per unit volume. Because of this, SMA&#39;s can generate a relatively large force over a longer displacement as compared to other materials of the same size. Additionally, because of the electrical resistance characteristics of SMA material, joule heating can be used to raise the SMA material to its austenitic phase transformation temperature. Furthermore, the electrical resistance characteristics of SMA material results in a strain-dependent electrical resistance effect at the phase transformation temperature.  
           [0003]    The two significant physical properties of SMA material, i.e., high recoverable strain and high actuation energy densities, have led to the development of SMA materials and devices for various applications. Bulk or thick film SMA materials are produced using traditional metal forming processes and are incorporated into many different devices ranging from orthodontia appliances to visored helmets. In these applications the bulk or thick film SMA materials take the form of wires, springs, thread fasteners, ring clamps, etc. Thin film SMA materials are produced by depositing an alloy on a substrate and have gained acceptance in micro fluidics and temperature related applications, particularly as actuators. Typically, applications utilizing bulk or thick film SMA materials exploit the one-way shape-memory property of SMA material. In these applications the bulk or thick film SMA material is strained (deformed) in the low temperature martensite phase and recovers to its parent shape upon being heated to the temperature at which the SMA material is transformed to its high temperature austenite phase. The strain-dependent electrical resistance effect of SMA material, however, has not been utilized for strain measuring devices or sensors because of the thermodynamic inefficiency of bulk or thick film SMA material. The hysteresis characteristics of bulk or thick film SMA material, which determine the phase transformation cycle period, are too slow (on the order of seconds) to be effective as a sensor. The slowness of the hysteresis characteristics of bulk or thick film SMA material is caused by the high thermal mass of this material. In contrast, due to the low thermal mass of thin film SMA material, the hysteresis characteristics of this material are quite fast (on the order of cycles/second) which makes thin film SMA material particularly suitable for certain applications, such as sensors, where the change in electrical resistance at a phase transformation of this material can be correlated to a change in strain being applied to the material. A problem, however, arises with thin film SMA material due to the difficulty in producing reliable thin film SMA materials that can repeatedly and consistently provide accurate strain measurements. Recent advances in manufacturing techniques, however, have resulted in the production of thin film SMA materials that exhibit a consistent quality suitable for use in strain measuring devices. Because of these manufacturing advances, it has become desirable to develop a sensor and method for measuring strain utilizing thin film SMA materials.  
         SUMMARY OF THE INVENTION  
         [0004]    The present invention provides a method and sensor for detecting strain using shape memory alloys. The sensor comprises a substrate material, a flexible diaphragm provided on the substrate material and a sensor member deposited on the flexible diaphragm. The sensor member is formed from a thin film SMA material and is capable of undergoing a phase transformation, such as from its martensite phase to its austenite phase, in response to a physical stimulus, such as strain, being applied thereto. During such a phase transformation, the electrical resistance of the thin film SMA material undergoes a substantial change. This change in electrical resistance can be correlated to a change in strain being applied to the thin film material. In this manner, the magnitude of the strain can be determined. The present invention also provides a method for measuring a physical stimulus comprising the steps of providing a sensor comprising a thin film SMA material; measuring a physical property, such as the electrical resistance, of the thin film SMA material immediately before the material undergoes a phase transformation caused by the application of a physical stimulus thereto; applying a physical stimulus to the thin film SMA material causing the material to undergo a phase transformation; measuring a physical property, such as the electrical resistance, of the thin film SMA material immediately after the material undergoes a phase transformation; determining the difference in the value of the physical property, i.e., the electrical resistance, that occurs during the phase transformation; and utilizing the difference in the value of the physical property to determine the magnitude of the physical stimulus being applied to the thin film SMA material. 
       
    
    
     BRIEF DESRIPTION OF THE DRAWINGS  
       [0005]    [0005]FIG. 1 is a hysteresis curve of Electrical Resistance or Length Change or Volume Change vs. Temperature for a hypothetical SMA material.  
         [0006]    [0006]FIG. 2 is a graph of Electrical Resistance vs. Temperature and shows the hysteresis curve of a thin film SMA material under three different strain levels.  
         [0007]    [0007]FIG. 3 is a graph of Electrical Resistance vs. Loading Condition for a thin film SMA material subjected to an increasing strain level from 0-1.2%.  
         [0008]    [0008]FIG. 4 is a Best Fit Line Graph of Electrical Resistance vs. Strain showing the linear response therebetween for a thin film SMA material.  
         [0009]    [0009]FIG. 5 is a top plan view of a thin film SMA material strain sensor.  
         [0010]    [0010]FIG. 6 is a cross-sectional view of a thin film SMA material strain sensor taken across section-indicating lines  6 - 6  of FIG. 5.  
         [0011]    [0011]FIG. 7 is a top plan view of a thin film SMA material strain sensor including a temperature measuring element and a heating element.  
         [0012]    [0012]FIG. 8 is an electrical schematic of four thin film SMA material strain sensors in a Wheatstone Bridge configuration. 
     
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0013]    The present invention relates to a method and sensor to detect strain utilizing the strain-dependent electrical resistance effect of SMA materials at their phase transformation temperature. The strain can be produced by any external stimulus, such as mechanical vibration, pressure, force, stress or other strain inducing external input.  
         [0014]    Referring now to FIG. 1, hysteresis curves of Electrical Resistance or Length Change or Volume Change vs. Temperature for a hypothetical SMA material is shown for three different levels of strain, i.e., zero strain, moderate strain, and high strain. In each instance, the bottom portion of each curve represents the material when in the martensite phase and the top portion of each curve represents the material when in the austenite phase. The portions of each curve interconnecting the bottom portion of the curve with the top portion of the curve represents a phase transformation, i.e., either from the martensite phase to the austenite phase or from the austenite phase to the martensite phase. As can be seen, each curve has a similar shape and as strain increases, the curves shift in a positive direction along the X and Y axes. Upon heating, the SMA material spontaneously transforms from the martensite phase to the austensite phase at the phase transformation temperature (the velocity of transformation is the acoustic velocity). The phase transformation temperature is a relatively narrow band of temperatures. Many of the physical properties of a SMA material, including electrical resistance, ductility, Young&#39;s Modulus, reflectivity, etc., undergo a substantial change in value during a phase transformation. The present invention relates to the large change in electrical resistance that occurs in SMA material during a phase transformation.  
         [0015]    It has been found that when an SMA material is held at or near its phase transformation temperature, an application of strain to the material causes the material to undergo the phase transformation with a corresponding large change in the electrical resistance of the material. The amount of strain required to induce the transformation may be quite small, on the order of 0.1% or less. The figure of merit for strain gages is called the gage factor and is defined as the normalized change in electrical resistance divided by the change in strain (Gage Factor=G.F.=((ΔR/R)/ε), where R is the electrical resistance; ΔR is the change in the electrical resistance; and ε is the strain. The gage factor for typical metal film strain gages is on the order of 2. Silicon and polycrystalline silicon piezoresistors have gage factors that vary from less than 1 to over 100 depending upon their orientation, doping level and crystalline perfection. However, this level of gage factor is quite difficult to achieve in practice. Furthermore, the high gage factor of silicon materials is lost when operated at elevated temperatures. The change in the electrical resistance of SMA material at its phase transformation temperature can, however, be on the order of 20% for a strain of 0.1%, thereby achieving a gage factor of nearly 200 (ΔR/R=0.2 and ε=0.001; therefore, 0.2/0.001=200). Also, SMA materials can have phase transformation temperatures in excess of 550° C. and, therefore, can be utilized in highly sensitive strain sensors at elevated temperature. The present invention discloses a method and a sensor utilizing SMA material to utilize this effect.  
         [0016]    The SMA material can be, but is not limited to, binary and equal parts (atomic weight percent) of elements, binary and unequal parts of elements, or ternary or quaternary parts of various compositions of elements. These compositions may comprise elements such as a mixture of titanium and nickel (TiNi) or titanium, nickel and palladium (TiNiPd) although it can be appreciated by one having ordinary skill in the art that the present invention is not limited to SMA material comprised of the aforementioned elements. Variations in composition and alloying content affect the temperature at which a phase transformation occurs. For example, in a SMA material comprising TiNi having approximately 50% atomic weight of each element, a 1 to 2% change in the percentage of titanium to nickel shifts the phase transformation temperature from below 0° C. to over 90° C. Thus, the phase transformation temperature can be stoichiometrically tailored by utilizing binary alloys and can be extended by using ternary alloys. A SMA material comprising TiNiPd can have a phase transformation temperature as high as 550 to 600° C. depending upon the relative concentration of Pd to Ni. As Pd is substituted for Ni, the phase transformation temperature increases until the resulting compound is completely TiPd whereupon the phase transformation temperature is at its maximum.  
         [0017]    Referring now to FIG. 2, there is shown a graph of Electrical Resistance vs, Temperature illustrating the hysteresis curves of SMA material under strain levels of 0.12%  12 , 0.23%  14  and 0.35%  16 . Each hysteresis curve has an austenite start point  121 ,  141  and  161 ; an austenite finish point,  122 ,  142  and  162 ; a martensite start point  123 ,  143  and  163 ; and a martensite finish point  124 ,  144  and  164 , defining individual hysteresis curves. As the temperature of the SMA material increases, it reaches the austenite start point  121 ,  141 ,  161  and the austenite phase transformation begins. The electrical resistance of the material decreases until it reaches its austenite finish point  122 ,  142 ,  162 . As the temperature of the SMA material is then decreased, the material reaches its martensite start point  123 ,  143  and  163  and the martensite phase transformation begins. The electrical resistance of the material increases until the material reaches its martensite finish point  124 ,  134  and  164 . As is evident from the graph, the hysteresis curves shift in response to changing strain, generally moving in a positive direction with respect to both the X and Y axes in response to increasing strain. This “shifting” characteristic causes the electrical resistance of the SMA material to change with respect to both temperature and strain.  
         [0018]    In one application of the present invention, the SMA material is heated to its austenite start point and then maintained at that temperature. As the strain increases, the electrical resistance of the SMA material at the austenite start point is measured. In FIG. 2, at approximately 45° C., this electrical resistance is 4.78 ohms for 0.12 strain  121 , 5.04 ohms for 0.23% strain, and 5.12 ohms for 0.35% strain. In another application of the present invention, the SMA material is heated past its austenite phase transformation point, and then cooled to its martensite start point and maintained at that temperature. As the strain increases, the electrical resistance of the SMA material at the martensite start point is measured. In FIG. 2, at approximately 60° C., this electrical resistance is 4.28 ohms for 0.12% strain  123 , 4.43 ohms for 0.23% strain and 4.46 ohms for 0.35% strain. In still another application of the present invention, the SMA material is heated and subsequently cooled through its entire hysteresis curve while maintaining strain substantially constant. The characteristics of the resulting curve are compared to other hysteresis curves in a “look-up” table to determine the value of the average strain being applied to the SMA material.  
         [0019]    Referring now to FIG. 3, there is shown a graph of Electrical Resistance vs. Loading Condition for a thin film SMA material subjected to an increasing strain level from 0-1.2%. As can be seen from this graph, the electrical resistance of the thin film SMA material increases in a substantially linear manner, from 5.49 ohms to 5.95 ohms, with an increase in the level of strain from 0.12% to 1.16%. Also, it can be seen that the electrical resistance of the material returns to nearly the same value (approximately 5.49 ohms) when the strain is removed. The loading condition corresponds to pressure or force applied to the thin film SMA material which produces the strain thereon.  
         [0020]    [0020]FIG. 4 is a Best Fit Line Graph of Electrical Resistance vs. Strain. This graph illustrates the substantially linear response of the thin film SMA material to the application of strain applied thereto. The Best Fit Line  36  has an R 2  value of 1.00 and is defined by the equation y=45.82x+5.41.  
         [0021]    Referring now to FIG. 5, there is shown a top plan view of a SMA material strain sensor  40 . A sensor element  42  formed from thin film TiNi material is deposited over a flexible diaphragm  44  on a substrate  46 . Typically, the flexible diaphragm  44  has an area of approximately 1 mm 2  whereas the substrate  46  has an area of approximately 1 cm 2 . Sensor terminals  48   a  and  48   b  provide electrical connection points for leads (not shown) for attachment of the sensor element  42  to external measuring devices or controllers, When a strain is applied to the flexible diaphragm  44 , the sensor element  42  flexes. Since the sensor element  42  is at the martensite/austenite phase transformation temperature, the sensor element  42  readily flexes and exhibits substantially linear electrical resistance vs. strain characteristics. The electrical resistance of the sensor element  42  increases as the strain applied thereto increases. The electrical resistance of the sensor element  42  can be transmitted through the sensor terminals  48   a  and  48   b  to external measuring devices or controllers. For example, a change in the electrical resistance of the sensor element  42  can be transformed into a change in the voltage drop across same. In view of the foregoing, the SMA strain sensor  40  can be utilized in a control circuit where a change in pressure or force is being monitored. An example of such a circuit is illustrated in FIG. 8 which is an electrical schematic of four SMA strain sensors  40   a ,  40   b ,  40   c , and  40   d  connected in a basic Wheatstone Bridge circuit  60 . Because of their electrical resistive characteristics, the SMA strain sensors  40   a ,  40   b ,  40   c  and  40   d  can be utilized in any Wheatstone Bridge circuit application in which the change in output voltage corresponds to change in strain.  
         [0022]    Referring now to FIG. 7, there is shown a top plan of the SMA material strain sensor  40  illustrated in FIG. 4 but further including a temperature measuring element  52  and a heating element  54 . The temperature measuring element  52  and heating element  54  are used to ensure that the temperature of the sensor element  42  is maintained at the phase transformation temperature. The temperature measuring element  52  can be any suitable temperature measuring device whereas the heating element  54  can be a resistance heater integrated into the sensor element  42 , or can be separate therefrom. The temperature measuring element  52  is located on the flexible diaphragm  44  to provide an accurate measurement of the temperature of the sensor element  42 . Typically, the flexible diaphragm  44  is a thin diaphragm resulting in low power consumption and fast thermal response. Temperature terminals  56   a  and  56   b  provide a connection between the temperature measuring element  52  and external temperature measuring devices. The heating element  54  is located on the diaphragm  44  to provide a substantially uniform temperature to the sensor element  42 . The heating element  54  is also capable of varying the temperature of the sensor element  42  through the phase transformation process. Heater terminals  58   a  and  58   b  provide connection between the heater element  54  and an external power source when the environment is cooler than the phase transformation temperature. In this manner, the sensor  40  can be operated above ambient temperature and the sensor operation can be tailored for optimum sensitivity.  
         [0023]    Certain modifications and improvements will occur to those skilled in the art upon reading the foregoing. It is understood that all such modifications and improvements have been deleted herein for the sake of conciseness and readability, but are properly within the scope of the following claims.