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Ames, IA, United States

Patent
Etrema Products, Inc. | Date: 2013-01-31

A product, such as one or more thin sheets, each containing a single or near-single crystalline inclusion-containing magnetic microstructure, is provided. In one embodiment, the inclusion-containing magnetic microstructure is a Galfenol-carbide microstructure. Various methods and devices, as well as compositions, are also described.


Grant
Agency: Department of Defense | Branch: Navy | Program: STTR | Phase: Phase I | Award Amount: 99.82K | Year: 2010

Energy harvesting devices utilizing magnetostrictive materials are a logical choice for harvesting the high impedance (high force, low displacement) vibrations found aboard Navy ships. Force-based devices, enabled by magnetostrictive materials, can harvest energy over an extremely large bandwidth, approximately ±35 and ±70 Hz currently, making them more desirable in situations aboard Navy ships were transient vibration conditions created by varying ship speeds is present. This broader bandwidth also means easier installation of the devices without the need for exact placement on the vibration source and eliminating tuning requirements typical of the displacement based devices. The robustness and formability that Galfenol alloys exhibit allow 1-dimensional (1D), 2-dimensional (2D), and 3-dimensional (3D) energy harvesting devices to be developed and optimized for the identified need and vibration coupling scheme. A 1D Galfenol device could consist of wire(s) bundled together to form an energy harvesting cable that could be wrapped around a vibrating column; a 2D Galfenol device could consist of a single Galfenol sheet attached to a vibrating panel; and a 3D Galfenol device could consist of structural support on-which the vibration source is mounted. The proposed work will investigate 1D and 2D Galfenol energy harvesting devices in Navy ship environments.


Grant
Agency: Department of Defense | Branch: Navy | Program: STTR | Phase: Phase II | Award Amount: 499.70K | Year: 2009

In the Phase I effort a Galfenol-based slotted cylinder projector (SCP) device was conceived utilizing an existing PZT SCP design and analytical modeling to determine the geometry requirements necessary to achieve the performance specs: 210 dB source level, 750 Hz resonance frequency, 200 Hz bandwidth. The final form factor was a Galfenol SCP with overall dimensions of 7.75” diameter x 12” length utilizing a graphite composite shell material with Galfenol drivers comprising a rib-like structure within the shell. The technical objectives in Phase II will include design optimization through improved modeling efforts, the development of manufacturing processes capable of producing the Galfenol rib structures, and the construction and testing of one complete transducer system. Device test data will be compared to predicted performance results via the developed model. A design iteration will be completed on paper along with beginning investigations into reducing manufacturing costs.


Grant
Agency: Department of Defense | Branch: Navy | Program: STTR | Phase: Phase II | Award Amount: 499.51K | Year: 2008

Etrema Products, Inc. and Applied Research Laboratory at The Pennsylvania State University demonstrated during Phase I that by utilizing the “delta-E” effect in magnetostrictive materials, the resonant frequency of a split ring transducer can be shifted by over 200 Hz for a low frequency transducer. A variable reluctance driver helps achieve source levels in excess of 210 dB with a potential 80% cost reduction as compared with a similar PZT transducer. The Phase II effort will focus on building hardware and verifying the performance and cost, and scalability of the transducer. Objectives of the Phase Base II effort are: 1. Identify the most viable compliance hinge mechanism and controller algorithm, 2. Demonstrate feasibility of the variable reluctance driver, 3. Demonstrate technical feasibility of the transducer including the controller. The Phase II Option Objectives are: 4. Identify performance limits of the transducer by testing the first article transducers, 5. Demonstrate the transition potential of the technology by optimizing the transducer design. Successful completion of the Phase II and Phase II Option efforts will result in a low-cost, low-frequency transducer design that can be transitioned to Navy applications.


Grant
Agency: Department of Defense | Branch: Navy | Program: SBIR | Phase: Phase II | Award Amount: 599.54K | Year: 2008

The Phase I effort successfully developed an integrated magnetostrictive transducer/amplifier module concept to meet these performance goals: broad bandwidth (7-30 kHz), compact size (approximately ½ wavelength at the center frequency), at least 30 Watts output power, and high efficiency. Conceptual designs of the transducer, amplifier, and the integrated transducer module developed during Phase I will be proven with hardware demonstrations during Phase II. The transducer is a hybrid Terfenol-D/Galfenol multiresonant tonpilz. The amplifier is a compact version of QorTek’s proprietary amplifier technology. Broadband performance was achieved by switching phase of the mechanical response between the Terfenol-D and Galfenol at a specified frequency which can be implemented in the amplifier and control electronics. In order to demonstrate the integrated transducer technology, the following objectives must be achieved in the proposed work: • Objective 1. Validate transducer and amplifier behavior using modeling and limited hardware demonstrations. • Objective 2. Demonstrate the integrated transducer/amplifier by building and testing integrated transducer modules. • (Option 1) Objective 3. Design an array of integrated modules to demonstrate capabilities of the module. • (Option 2) Objective 4. Demonstrate the technology to enable review and adoption by Navy transition program offices.

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