The goal of this work is to build model credibility of a structural dynamics model by comparing simulated responses to measured responses in random vibration environments, with limited knowledge of the true test input. Oftentimes off-axis excitations can be introduced during single axis vibration testing in the laboratory due to shaker or test fixture dynamics and interface variation. Model credibility cannot be improved by comparing predicted responses to measured responses with unknown excitation profiles. In the absence of sufficient time domain response measurements, the true multi-degree-of-freedom input cannot be exactly characterized for a fair comparison between the model and experiment. Methods exist, however, to estimate multi-degree-of-freedom (MDOF) inputs required to replicate field test data in the laboratory Ross et al.: 6-DOF Shaker Test Input Derivation from Field Test. In: Proceedings of the 35th IMAC, A Conference and Exposition on Structural Dynamics, Bethel (2017). This work focuses on utilizing one of these methods to approximately characterize the off-axis excitation present during laboratory random vibration testing. The method selects a sub-set of the experimental output spectral density matrix, in combination with the system transmissibility matrix, to estimate the input spectral density matrix required to drive the selected measurement responses. Using the estimated multi-degree-of-freedom input generated from this method, the error between simulated predictions and measured responses was significantly reduced across the frequency range of interest, compared to the error computed between experimental data to simulated responses generated assuming single axis excitation.
Pyrolyzed carbon as a mechanical material is promising for applications in harsh environments. In this work, we characterized the material and developed novel processes for fabricating carbon composite micro-electromechanical systems (CMEMS) structures. A novel method of increasing Young's modulus and the conductivity of pyrolyzed AZ 4330 was demonstrated by loading the films with graphene oxide prior to pyrolysis. By incorporating 2 wt.% graphene stiffeners into the film, a 65% increase in Young's modulus and 11% increase in conductivity were achieved. By reactive ion etching pyrolyzed blanket AZ 50XT thick film photoresist, a high aspect ratio process was demonstrated with films >7.5um thick. Two novel multi-level, volume-scalable CMEMS processes were developed on 6" diameter wafers. Young's modulus of 23 GPa was extracted from nanoindentation measurements of pyrolyzed AZ 50XT films. The temperature-dependent resistance was characterized from room temperature to 500C and found to be nearly linear over this range. By fitting the results of self-heated bridges in an inert ambient, we calculated that the bridges survived to 1000C without failure. Transmission electron microscopy (TEM) results showed the film to be largely amorphous, containing some sub-micrometer sized graphite crystallites. This was consistent with our Raman analysis, which also showed the film to be largely sp 2 bonded. The calculated average density of pyrolyzed AZ 4330 films was 1.32 g/cm 2 . Thin level of disorder and the conductivity of thin film resistors were found to unchanged by 2Mrad gamma irradiation from a Co 60 source. Thin film pyrolyzed carbon resistors were hermetically sealed in a nitrogen ambient in 24-pin dual in-line packages (DIP's). The resistance was measured periodically and remained constant over 6 months' time.
In this research, a new type of highly stretchable strain sensor was developed to measure large strains. The sensor was based on the piezo-resistive response of carbon nanotube (CNT)/polydimethylsiloxane (PDMS) composite thin films. The piezo-resistive response of CNT composite gives accurate strain measurement with high frequency response, while the ultra-soft PDMS matrix provides high flexibility and ductility for large strain measurement. Experimental results show that the CNT/PDMS sensor measures large strains (up to 8 %) with an excellent linearity and a fast frequency response. The new miniature strain sensor also exhibits much higher sensitivities than the conventional foil strain gages, as its gauge factor is 500 times of that of the conventional foil strain gages.
This report describes activities conducted in FY07 to mature the MEMS passive shock sensor. The first chapter of the report provides motivation and background on activities that are described in detail in later chapters. The second chapter discusses concepts that are important for integrating the MEMS passive shock sensor into a system. Following these two introductory chapters, the report details modeling and design efforts, packaging, failure analysis and testing and validation. At the end of FY07, the MEMS passive shock sensor was at TRL 4.