Etrema Presentation Mrs 2011

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



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




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




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




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)



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)




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




•

Excessive (Tb, Dy) losses can lead to RFe3

phase and/or Widmanstatten precipitates

•

Symmetry disruption and domain wall pinning



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




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



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



ETREMA Products, Inc.Actuator Video



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.




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

http://www.etrema.com/




CU18A + Horn

ApplicationsUltrasonic sourceMicro positioningSono-Chemistry

CU18 with 20.5 kHz horn attached



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.



ETREMA Products, Inc.Cavitation



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




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




-

Image taken from Woods Hole Oceanographic Institute website

SSAM on REMUS 600 AUV




-

Image taken from Woods Hole Oceanographic Institute website

-

Image taken from Proceedings of the MTS/IEEE OCEANS 2006 Boston Conference and Exhibition




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




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)



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




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




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




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




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




Galfenol Components

Laminated and machined threads

Forged and machined shapes

Laminated and milled stack




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



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




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



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

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