45th AIAA/ASME/ASCE/AHS/ASC Structures, Structural Dynamics & Materials Conference AIAA 2004-1888

19 - 22 April 2004, Palm Springs, California

Morphing Wing Structures for Loitering Air Vehicles

David A. Perkins, John L. Reed, Jr., Ernie Havens

Cornerstone Research Group, Inc., 2750 Indian Ripple Road, Dayton, OH, 45440

ABSTRACT

Cornerstone Research Group Inc. (CRG) will present current results of ongoing research and development of
adaptive wing structures. The focus of these efforts is to develop and demonstrate viable composite materials and
process technology to support multiple structural morphing applications. Prototypes under development include
seamless-span morphing wings, chord morphing wings, and folding wings. Chord morphing is the focus of this
paper. Advanced technologies applied include CRG’s shape memory polymers (SMP) Veriflex™, dynamic modulus
composites (DMC) Veritex™, and dynamic modulus foams (DMF) Verilyte™. The development approach includes
internal structure, seamless skin, thermal activation, and mechanical actuation. Many new composite fabrication
techniques have been investigated. Other technologies under consideration include shape memory alloys,
piezoelectric materials, electro- and magneto-rheological materials.
Initial design and engineering efforts have focused on integrating new adaptive materials technologies into standard
composite structures. CRG developed preliminary prototype designs of adaptive wing structures, developed a
processing approach for fabrication, validated previously undemonstrated fabrication processes, and fabricated
independently functional subsections of a morphing wing to prove feasibility.

Keywords: Adaptive structures, morphing aircraft, smart materials, shape memory materials

1. INTRODUCTION

Many aircraft are designed solely to operate in a single flight profile, such as a maneuverable fighter or a
long-range cruise airliner. If an aircraft is designed to be a hybrid and combine several flight profiles, the wings
must be designed to maximize overall efficiency, causing the efficiency in each individual flight regime to be less
than the efficiency of an aircraft designed for that regime. Significant improvements can be made to these hybrids
by implementing a wing that can change its shape to match the most efficient form for any flight regime. The
change in wing shape would allow the aircraft to adjust between an aspect ratio suited for long-range cruise and one
suited for maneuvering. The aircraft flies to a point in a cruise-efficient wing shape and upon reaching its target
location morphs to a wing shape more efficient for maneuvering.
L = 1 ρ v 2 SCL (1.1)
2
CRG investigated an increase in lift by dramatically increasing the planform area (S) and therefore the lift
generated according to Bernoulli’s Equation (Eq. 1.1), where L is the lift, v is the velocity of the aircraft, ρ is the
local air density, and CL is the coefficient of lift. CRG began with the goal of increasing lift by 80%.

CRG proposed to accomplish this endeavor with significant effort focused on design and engineering by
integrating new adaptive materials technologies, including shape memory polymers (SMP), dynamic modulus
composites (DMC), and dynamic modulus foam (DMF), into standard composite structures. The Phase I research
effort was focused on proving the feasibility of the design and provided the groundwork for full-scale prototype
testing and design in Phase II. During Phase I, CRG developed a preliminary prototype design of an adaptive wing
structure for the morphing aircraft, as well as related actuation and activation components. CRG also developed a
processing approach for fabrication of the wing and smart material composite skins, validated undemonstrated
fabrication processes, investigated scale-up processes, and fabricated and validated sub-scale prototypes of the
morphing wing components to prove feasibility. During Phase II, CRG plans to demonstrate the concept by
fabricating a full-sized, working prototype ready for integration into existing loitering UAV systems.

Copyright © 2004 by the American Institute of Aeronautics and Astronautics, Inc. All rights reserved.
Smart materials technologies developed
The next sections describe a suite of smart materials CRG has developed for the use in adaptive structures,
such as morphing wings.

Shape memory polymer

First introduced in the United States in 1984, shape memory polymers (SMPs) are polymers whose
qualities have been altered to give them dynamic shape “memory” properties. Under thermal stimuli, shape memory
polymers can exhibit a radical change from a rigid polymer to a very flexible, elastic state, then back to a rigid state
again. In its elastic state, SMP will recover its “memory” shape if left unrestrained. The “memory,” or recovery,
quality comes from the stored mechanical energy attained during the reconfiguration and cooling of the material.
SMP’s ability to change stiffness modulus and shape configuration at will makes it ideal for applications requiring
lightweight, dynamic, adaptable materials. Unlike a shape memory alloy (SMA), SMP exhibits a radical change
from a normal rigid polymer to a very flexible elastic and back on command, a change that can be repeated without
degradation of the material. The SMP transition process is a thermo-molecular relaxation rather than a thermally-
induced crystalline phase transformation, as with SMA. In addition, SMP demonstrates much broader range and
versatility than SMA in shape configuration and manipulation.

SMP is not simply an elastomer, nor simply a plastic. It exhibits characteristics of both materials depending
on its temperature. While rigid, SMP demonstrates the strength-to-weight ratio of a rigid polymer; however, normal
rigid polymers under thermal stimulus simply flow or melt into a random new shape, and have no “memorized”
shape to which they can return. While heated and pliable, SMP has the flexibility of a high-quality, dynamic
elastomer, tolerating up to 200% elongation; however, unlike normal elastomers, SMP can be reshaped or returned
quickly to its memorized shape and subsequently cooled into a rigid plastic. Figure 1.1 shows the elastic modulus of
SMP in relation to temperature. Figure 1.2 shows a chart of storage modulus (stiffness) versus temperature, showing
the initial range of CRG’s patented styrene SMP with activation temperatures customizable to between 110°F and
220°F (47°C to 106°C).1

Figure 1.1 – SMP elastic modulus versus Figure 1.2 - DMA graph of various styrene SMP
temperature storage moduli
There are three types of SMP: 1) partially cured resins, 2) thermoplastics, and 3) fully cured thermoset
systems. In several years of research, CRG has found limitations and drawbacks to the first two types of SMP.
Partially cured resins continue to cure during operation and change properties with every cycle. Thermoplastic SMP
“creeps,” which means it gradually “forgets” its memory shape over time. With this supporting research and a
thorough understanding of the chemical mechanisms of SMP, CRG has developed fully cured, high-performance
thermoset systems.2 CRG has also demonstrated lab-scale feasibility on many new SMP formulations and are
investigating triggering mechanisms other than heat such as light, electric field, or magnetic field. CRG has a
trademarked SMP material, called VeriflexTM.
 As stated, above its transition temperature, in its elastic state, SMP will recover its “memorized” or cured
shape very quickly if left unrestrained, a quality useful in deployment applications. In addition, while heated and
pliable it can be stretched, folded, rolled, twisted, bent, or otherwise reconfigured or manipulated into other shapes.
The SMP can be cooled to maintain its altered shape for as long as necessary until once again it is heated above its
transition temperature. This thermal reconfiguration process can be repeated indefinitely without losing material
integrity. Both SMP’s memorized shape and its manipulated reconfigurations will maintain shape integrity over time
below transition temperature. It can be cast and cured into a variety of “memorized” shapes, from thick sheets and
concave dishes to tiny parts or a complicated open honeycomb matrix (Figure 1.3).

Original Stowed Shape 1st Recovery Snapshot 2nd Recovery Snapshot

Fully Recovered

Figure 1.3 - Snapshot series of a shape memory polymer honeycomb structure

self-recovering under an IR heat lamp. The memorized shape is the honeycomb.
The temporary stowed shape was the result of compressing and rolling the
structure while warm and then cooling to maintain the stowed shape.

Dynamic modulus composites

Dynamic modulus composites (DMCs) are like other high-performance composites, except CRG’s
Veriflex™ resin is used as the matrix. Fabrication with Veriflex™ resin allows easy manipulation of the composite
above the activation temperature and high strength and stiffness at lower temperatures. The composite acquires
some SMP characteristics, making it a unique material for use in dynamic structures and other applications requiring
both load strength and “shape-shifting” modulus flexibility.

CRG’s version of DMC, Veritex™, capitalizes on the ability of the SMP resin to quickly soften and harden
repeatedly. Because of this property, the dynamic composites can be temporarily softened, reshaped, and rapidly
hardened in real-time to function as structures in a variety of configurations. They can be fabricated with nearly any
fiber type, and creative reinforcements can allow dramatic shape changes in functional structures. Veritex™ is also
machinable. Figure 1.4 shows VeritexTM tubes that can be flattened and rolled up for storage, then deployed when
needed.

Figure 1.4 - Tubes made of VeritexTM

 Some possible applications capitalizing on the versatility of Veritex™ include rapid manufacturing,
dynamic structures that can be stowed flat and subsequently set up, adaptable reinforcements, and portable,
lightweight, rigid, deployable structures that can be used as an alternative or enhancement to current inflatable
structures.

Dynamic modulus foam

Dynamic-modulus foam (DMF) is a low-density, adaptive structural composite foam system fabricated
using SMP resin that can be thermally softened and subsequently hardened. This feature provides the ability to
fabricate adaptive composite structures with a foam core, soften a structural foam element, alter its shape, and then
return it to a rigid state in its new configuration. The DMF can be reshaped multiple times. As with SMP and DMC,
DMF has a very narrow temperature range in which it transitions between hard and pliable. This narrow span allows
DMF to maintain full structural rigidity up to a specifically designed activation temperature, and this activation
temperature can be tailored.3 The DMF concept is depicted in Figure 1.5.

Figure 1.5 – Time-lapse illustration of the concept

Modify Confinement
of DMF core materials. DMF will conform to fill a
void and become rigid to provide internal
Compressed
Rigidified structural support. The void may change shapes
DMF indefinitely, and the DMF will re-conform on
Activate DMF to allow it to re- command to maintain, fill, and support.
conform and provide internal
structural fill

DMF core materials highlights:

• Rapidly fills remote voids on command and becomes rigid to provide lightweight structural support
• Functions as deployable/conformable lightweight internal structure, (see Figure 1.6)
• Shape is infinitely reconfigurable
• Supports adaptive structures concepts

Figure 1.6 – DMF blocks at full size and 400% compression

2. DESIGN METHODOLOGY

CRG developed preliminary prototype designs of adaptive wing structures, developed a processing
approach for fabrication, validated previously undemonstrated fabrication processes, and fabricated independently
functional subsections of a morphing wing to prove feasibility.
 An outline of the prototype design requirements is listed.
• The wing structure shall be aeroelastically stable throughout the morphing UAV flight envelope.
• The wing structure shall withstand a normal load factor of 6 for a 100-pound vehicle.
• The wing structure shall withstand, in the carriage configuration, the harsh military environments.
• The quarter chord of the wing shall remain at the same station; thus the chord ahead of the quarter chord
must grow at a rate 1/3 that of the chord aft of the quarter chord.
• There will be no forward facing or aft facing steps.
• The time required to “morph” between configurations shall not exceed 1 second.
• Lift must be increased by 80 percent.

The current processing approach involves an internal sliding rib structure, with a styrene-based SMP skin
wrapped from the top of the wing at the root, down the span, around the wing tip, and back to the wing root on the
bottom. This approach will minimize any effects from necking in the material, because any necking should only
occur at the wing root. Fairings can also be used at the root to cover the necking at the root if necessary. This
“spanwise” wrap is shown in Figure 2.1. Embedded heating wires will act as the activation system for the SMP.
Actuation remains a major issue with the wing. A suitable device that can fit in the volume of the wing and provide
sufficient force and displacement will be developed. Further work in Phase II will improve the design, fabricate,
and test a full-scale prototype of this morphing wing.

Figure 2.1 – The areas marked with red dashed lines depict the location of SMP skin. Each SMP skin area
will be fabricated from a long strip of SMP that will wrap “spanwise” from the top to the bottom around the
wing tip as depicted in the 3-D form on the right.

3. DESIGN ITERATIONS

The composite development approach concentrated on the methods of fabricating the required composites
and smart materials and then integrating the systems together. The critical experiments and demonstrations of the
components from the design task pointed to areas that needed improvement. These tasks were repeated in an
iterative process to develop the wing from the initial concept to the final Phase I concept.

Structure
The initial concept for the morphing wing can be seen in Figure 3.1. The concept consisted of an SMP or
DMC skin with an internal structure consisting of DMF. Sliding rods within the DMF would stop the expansion at
the required distance. Additional design efforts during the program focused on broadening the acceptability of the
technology bypassing the original one-way design for a two-way adjustable chord design.
 Figure 3.1 - Original UAV wing, which is nearly
optimal for cruise operations (Top Left). Proposed
adapted wing, which is needed for increased
maneuverability vital to the ideal mission
performance (Top Right). Cross-section of initial
wing concept (Right).

After an initial round of analysis and testing, it was determined that the DMF works very well for one-way
expansion, but not as well for the two-way expansion and contraction, which is preferred. The design was shifted
towards an internal structure consisting of either sliding or telescoping ribs with either a neat SMP or corrugated
DMC skin. This concept and subsequent prototype is shown in Figure 3.2. Basic sizing of the structural members
was accomplished by assuming an elliptical lift distribution across the main spar and assuming that the extra 80%
lift must be supported by the expanded chord ribs. First iteration analysis showed that aluminum is an acceptable
material for the design.

Figure 3.2 – Sliding ribs concept (Top) and prototyped segment (Bottom)

Skin
The accordion folded DMC, shown in Figure 3.3, was fabricated to investigate its applicability as a skin
material. This approach for skin material was interesting because the potential existed to have full composite
strength in the expanded state allowing shear flow through the skin of the wing box as with most traditional wing
designs. Demonstration of this material showed large forces were required to obtain a perfectly smooth surface,
otherwise small wrinkles were present which would be detrimental to drag performance. Further development of
this material may yield improved results, but at this time, the neat SMP is showing dramatically better results.

Figure 3.3 – Corrugated DMC skin investigations (Top two diagrams) Conceptual DMC performance,
(Bottom two pictures) Corrugated DMC demonstration

A simulator for the skin morphing process was built to test the neat SMP skin concept by inducing 125%
strain to match the needed expansion. This rapid deployment simulator (RDS) is shown in Figure 3.4 and used hot
air to activate the skin and then stretched and contracted it using two air pistons. Initially, styrene-based SMP skin
1/16” thick was used. This material was able to withstand two cycles on average before failure. In order to increase
the failure strength, the skin was increased to 1/8” thick. This material was able to withstand multiple cycles, but
was still too brittle in the hardened state for the expected vibration loads. The SMP used during Phase I was
originally developed for a molding application with very unique design criteria. As expected these experiments
demonstrated feasibility; however, they also demonstrated performance modifications are required for SMP to
perform optimally for this application. Original and new design criteria are outlined in Table 3.1.

Figure 3.4 – Rapid deployment simulator (RDS)

(Above left) and one stretching cycle of styrene SMP
(Above right; Right)
 Table 3.1 – SMP performance design criteria

Original SMP design criteria for molding New SMP design criteria for morphing aerospace
applications applications

– High cold modulus – High toughness

– Optical quality thermoforming – High tensile strength

– FDA approvable – High thermal conductivity

– Transparent – Highly compatible with fiber

– Rapid forming – VARTM compatible

– Chemically resistant

– Abrasion resistant

– UV resistant

Based on these results, CRG added an additional task to begin developing an aerospace grade SMP.
Although progress is still underway, significant improvements have been achieved. Based on recent results, CRG
expects to achieve 1/16”, or less, skin thickness. Figure 3.5 shows qualitatively a dramatic improvement in these
newly specified design parameters. A significant effort is still required to optimize the formulation and fully
characterize the properties.

Figure 3.5 – Qualitative results showing significant improvement in cold flexure strength. The sample on the
right in each picture is CRG’s new aerospace grade SMP (Still under development). The sample on the left of
each picture is the original SMP formulation developed for molding. (Left) Original samples. (Middle)
Results of a 30 degree flexure. (Right) Results of a 90-degree flexure.

Activation
The initial activation concept involved using the hot gasses from the exhaust as both a source of heat to
activate the skin and DMF structure and provide pressurized air for actuating the wing. Early in the investigation, it
was determined that plumbing issues could complicate the wing, and hot exhaust air was de-selected from the list of
possible actuation and activation methods. Without access to the hot exhaust air as a heat source for activation, a
method for activating the skin from within the wing needed to be developed. Embedding heating wires into the skin
was successfully demonstrated. Initially, thin nichrome wires were embedded. At 40W, the wires were able to heat
the SMP above its transition temperature, but the heat distribution was not adequately uniform. The wires were
close to the thickness of the skin causing divots to form along each wire. The second iteration used very thin wires
placed much closer together. At 40W, the SMP was again heated above the transition temperature, but since the
resistance of the wire was increased, a higher voltage was required. The embedded heating wires and heat
distribution can be seen in Figure 3.6.

Figure 3.6– Heat distribution using liquid crystal thermography for SMP embedded with nichrome wires (26
AWG (Right); 36 AWG (Left)

4. CONCLUSIONS

The results of the Phase I work show that the design for an adjustable chord morphing wing is feasible.
Plans for Phase II include finalizing the wing structure design, developing a sound actuation design, developing an
aerospace grade SMP, fabricating a form, fit, functional morphing wing system, and demonstrating performance in
an operationally relevant wind tunnel environment.

Alternative conceptual development and investigation of multiple aspects of morphing technology are
being actively pursued over the course of this research and development effort. An example of other concepts to be
investigated include, but are not limited to, expansion of the chord while pivoting at the wing tip, shown in Figure
4.1. Since the lift distribution is elliptical, more lift is produced at the wing root. Therefore, an increase in chord at
the wing root will have the largest effect on increasing lift.

Figure 4.1 – Root chord expansion by pivoting at the wing tip

Research into these alternate designs will give CRG a greater insight into the possibilities created by
morphing wings. As the smart materials are improved, more complex designs can be developed and a large
improvement in air vehicle performance will be possible.

ACKNOWLEDGEMENTS

Dr. Michael Valentino, Air Force Research Laboratory

Capt. Jacob A. Freeman, Air Force Research Laboratory
Lockheed Martin
 REFERENCES

1. Tat H. Tong et al. “Studies of Shape Memory Behavior of Styrene-Based Network Copolymers”, Proceedings
of The First World Conference on Biomimetics, Albuquerque, NM, Dec, 2002.
2. Sean Cullen, "Thermomechanical Properties of Shape Memory Polymers," Proceedings of SAMPE Conference,
Long Beach, CA, May, 2003.
3. Lisa Culver et al. “Thermally Conductive Dynamic Modulus Foam”, Proceedings of SAMPE Conference, Long
Beach, CA, May, 2003.
4. David A. Perkins et al. “Adaptive Wing Structures”, Proceedings of SPIE Conference, San Diego, CA, March,
2004