000009

Modeling and Characterization of Active Fiber Composites

·Alberto Bellolia, Benedetto Castellia, Xavier Kornmannb"Christian H~berb
and Paolo Ermannia
acentre of Structure Technologies, ETH -, Swiss Federal Institute of Technology, Zurich,
Switzerland.
bEMPA - Swiss Federal Laboratories for Materials Testing and Research, Duebendorf,
Switzerland

ABSTRACT
' manufacturing of sensors and actuators made of piezo-
The scientific community has put significant efforts in the
ceramic fibers with interdigitated electro.des. These allow for increased conformability and actuation capability
at high field regime. The prediction of their coupled field behavior, however, is so far limited to low field ap-
plications, where the piezoelectric coupling coefficient is assumed to be constant. An appro.ach, which takes
into account the strain driven nonlinearity of a rep'resentative work cycle at high field regime is still lacking.
This study presents a nonlinear Finite Element Model to simulate the free strain properties of Active Fiber
Composites (AFCs) under high electric field conditions. Input data for the fully parametric model are the Rep-
resentative Volume Element (RVE) geometry .and the material properties of its piezoceramic and epoxy resin
components. The high field properties of single PZT fibers under free strain conditions were determined using
a novel characterization :procedure. Free strain properties of the actuators were measured experimentally, and
important geometrical parameters (contact angle between the fiber and the electrode, average spacing between
the fibers) were measured using micrographical imaging. The results of the simulation show good agreement with
the free strain measurements, allowing for prediction of a representative work cycle hysteresis. The influeii.ce
of important geometrical parameters on the actuator properties such as electrode spacing and. electrode-fiber
.contact angle was i~vestigated. both numerically and experimentally.

1. INTRODUCTION
Active ·Fiber Composites (AFCs) originated from work stf:l,rted at MIT in 1992 1 . AFCs are composed of PZT
(lead zirconate titanate) fibers and epoxy resin. Interdigitated electrodes (IDEs) are used for poling and to
direct the electric field along the longitudinally oriented PZT fibers (see Figure 1 ). AFCs achieve greater
actuation energy density by exploiting the d 33 effect along the fibers versus the d 31 actuation used in most
monolithic piezoceramic materials. The use of piezocerarnic fibers maintains the majority of the stiffness and
the bandwidth of pure piezoceramics, by simultaneously achieving high conformability and thus integrability in
complex <:urved structures. Furthermore, they allow for anisotropic actuation. These properties make AFCs
interesting components for applications in different fields, such as shape and vibration control.
Analytical and numerical methods were used to predict the performances of AFCs. In his PhD thesis, Bent 2
proposes an analytical model as summation of parallel and series additions of two phase materials. The resulting
Uniform Fields Model (UFM) is thus a generalization of the well known "Rules of Mixtures;' and assumes the
uniformity of the electric and mechanical fields in each phase. Compatibility and equilibrium are violated at
some interfaces. The UFM simplifies the AFC's complex geometry, thus not taking into account the electric
field distortion under the electrode fingers. Nevertheless, it provides a closed form solution that allows physical
insight into the problem. The AFC geometry (i.e. circular fiber cross sections, electrode configuration) can be
fully modelled with FE, and electric field variations in the single phases can be visualized and quantified. This
is of special interest in the matrix gap between electrode and fiber and in the "dead-zone" under the electrode
finger, where the actuation is supposed to be very small or completely absent.
Send correspondence to A. Belfoli: E-mail: [email protected], Telephone: ++411 632 51 86, Address: IMES-
Centre of Structure Technologies, Lconhardstrasse 27, CH-8092 Zurich, Switzerland

Smart Structures and Materials 2004: Smart Structures and Integrated Systems,
edited by Alison B. Flatau, Proc. of SPIE Vol. 5390 (SPIE, Bellingham, WA, 2004)
0277-786X/04/$15 · doi: 10.1117112.539871
 The influence of configuration parameters on the actuation behavior of AFCs has been investigated by different
authors, however only for low field actuation. According to Rossetti 3 and Bent4 , AFCs with a small electrode
spacing p to fiber diameter d ratio show good actuation at lower voltages, but are less efficient due to the steep
curvature of the electric field in the vicinity of the electrode traces. Alternatively, larger p/d ratios are more
efficient, but require higher drive voltages to achieve actuatiOn at the same field levels. Nelson 5 claims that 80%
of the theoretical maximum strain can be achieved with a p/d ratio greater than 4.' Investigating the influence of
the interdigitated electrode structure on the strain response of a PZT bulk substrate, he identifies an optimum
electrode width to substrate thickness ratio of 0.5.
An approach is still lacking that predicts the strain driven nonlinearity observed in AFCs under free strain
conditions. In the scope of this study, a fully parametric FE model is implemented, which predicts the nonlinear
work cycle of different AFC configurations. A procedure is developed for the experimental characterization of
single PZT fibers. In particular, butterfly loops and work cycles are measured, later required for the model.
Manufacturing and characterization of corresponding AFCs allow for experimental validation of the numerical
results.

2. FE ANALYSIS
In the scope of this study, the response behavior of AFCs is predicted by a FE model. In or.der to minimize
computational requirements, an AFC unit cell is defined, that comprises all relevant parameters. Because of
symmetry, the so called Representative Volume Element (RVE) can be defined as an octant of a single fiber and
its surrounding matrix included between two adjacent electrode fingers (see Figure 1).

L-
-
S"y:rnetry plane

Figure 1. Schematic view of an Active Fiber Composite (AFC). The Representative Volume Element (RVE) is defined
as an octant of a single fiber and its surrounding matrix included in two adjacent electrode fingers.

2.1. Geometrical Parameters

The fiber diameter d, the fiber spacing b, the electrode width w, the electrode spacing p and the contact angle
<pare considered in the numerical model (see Figure 1). The angle of contact defines the portion of the circular
cross-section, which is in contact with the upper resp. lower electrode finger. In addition, the thickness of the
insulating polyimide foils is accounted for. w and p were obtained from the AFC manufacturer, whereas the

Proc. of SPIE Vol. 5390 79

 remaining parameters were investigated taking advantage of the micrographical imaging technique (see subsection
3.3.2). .

2.2. Material Properties

Stress piezoelectric constants, relative dielectric constants and stiffness constants are summarized in Table 3.
The experimentally obtained representative work cycle of the investigated AFC reveals a large nonlinear
response (see Figure 6). The strain driven nonlinearity becomes important for free strain conditions at high field
regime. Accordingly, the piezoelectric response has to be described with constants for low field, respectively
strain vs. electric field curves for high field applications.
Since no representative work cycle could be found in the literature, a novel procedure is proposed for the
characterization of single PZT fibres (see subsection 3.1). Polynomial interpolation yields characteristic curves
d 33 = f(E 3) for the upward resp. downward sectors of the measured work cycle to be implemented in the free
strain model presented in subsection 2.3.

2.3. The FE-Model

The AFC's behavior is predicted using ANSYS 7.1 Direct Coupled Field Analysis. SOLID 5, S-node 3D multifield
elements are used. The mesh is generated in a parametric way, thus assuring similar degree of accura~y for
different fiber diameters d and electrode spacings p. . .
The electrode is not explicitly modeled as shown in Figure 1, but defined as an electrical boundary condition.
According to Castelli 6 , the part of the electrode in the matrbc has only little effect on the fiber due to the low
resin dielectric constant c. Consequently, the electrode is only modeled on the fiber, but not in the matrix.·
A defined voltage is applied to the. nodes lying on the surface of the fiber and in the area 0 < z < w/2 and
0 < x < bc/2. Because of symmetry, the fiber is grounded at z = p/2 and the voltage on the electrode is U /2,
where U is the voltage applied to actuate the AFC.
Prediction of the AFC response under free strain conditions requires the implementation· of the nonlinear
piezoelectric coefficients (see Figure 2). For a continuous increase of the tension 'on the electrodes the homoge-
neous electric field is determined as (EPlz=~). Piezoelectric coefficients d 33 = f(E3) are computed using the
characteristic curves described in ·subsection 2.2. Values for d 31 and d 15 are computed in. accordance to the
expressions in Appendix A. Stress piezoelectric coefficients are updated according to the constitutive equations 7 :

(1)

where cE is the stiffness matrix. For each substep the electric field and free strain values are computed. Electrical
and mechanical boundary conditions are defined in Table 1.

Coordinate Mechanical Electrical

x=O U1 =0 D1=0
y=O U2 = 0 D2 =0
z=O U3 = 0 D3 =0
x = b/2 coupled u 1 D1:o=0
y = t/2 coupled u2 V = U/2 on electrode
(D2 = 0 elsewhere)
z =p/2 coupled U3 V=O
Table 1. Electrical and mechanical boundary conditions for the free strain model.

80 Proc. of SPIE Vol. 5390

 Figure 2. Implementation of daa in ANSYS.

3. MATERIALS AND METHODS

3.1. Materials
Piezoelectric ceramic fibers PZT-5A with a diameter of 255µm were supplied by -Smart Material Corporation,
Osprey, USA. Polyimide foils of Kapton 100 HN (25µm in thickness) supplied by Dupont, Mechelen, Belgium
were. used for the preparation of the screen-printed electrodes. The silver paste used for the ele<;:trodes was
the CB025 from Dupont. The two-component epoxy resin, Ai·aldite LY 564/Aradur 2954 from Vantico AG,
Basel, Switzerland, was used in combination with few drops of the antifoaming agent BYK-A530 supplied by
BYK-Chemie GmbH, Wesel, Germany as matrix for theActiv~_ l\ibe~ Composite. . ' '
The high field properties of PZT fibers were determined--using-a noyel-.Gharacterization-procedure-for-single-
fibers developed at the Centre for Structure Technologies8 . The strain versus electric field response of a single
fibre is measured usi~g a Dynamic Mechanical Analyzer. Its force control allows for free strain conditiOns during
the whole measurement. After poling at rooin temperature, butterfly loops were recorded. Work cycles were
then measured for electric field values ranging from -0.9kV/mm to 3kV/mm.

3.2. AFC Manufacture

Active fiber composites were manufactured by laminating a piezoelectric fiber mat constituted of approximately
75 fibers sandwiched between two screen-printed interdigitated electrodes and embedded in an epoxy matrbc. 9
The interdigitated electrodes had a finger width of approximately 200µm, a finger electrode spacing of 700, 900,
llOO, or 1300µm and a finger thiCkness of approximately 15µm. The active area of the electrode was 20mm in
width and 3lmm in length. The active fiber composites were cured under pressure (3.4MPa) in an hydraulic
press at 120°C for 1 hour. They were then post-cured 8 hours in an oven at 160°C. The active fiber composites
were poled through the interdigitated electrodes by applying an electric field of 2.8kV/mm to the AFC during
20 minutes in an oven at 80°C.

3.3. AFC Characterization

3.3.1. Free Strain Measurement
The free strain response of AFCs was measured thanks to standard 350il electrical resistance foil strain gauges
(Type 10/350LY11, lOmm in length, 5mm in width) supplied by HBM AG, Naenikon, Switzerland bonded
symmetrically on both sides of the AFCs and conriected in series to an amplifier via a half Winston bridge.
Electric fields between -1 and 3kV/mm were applied to the AFCs.in order to generate characteristic actuation
curves (i.e. work cycles).

Proc. of SPIE Vol. 5390 81

 3.3.2. Microscopy
AFCs were cut .at different angles and observed under the optical microscope. The measured entities were
statistically analyzed to obtain realistic parameters. These are listed in Table 2.

Figure 3. Geometrical parameters measured using the micrographical imaging technology 6 • Fiber diameter, fiber spacing,
contact angle and electrode thickness are described.

4. RESULTS AND DISCUSSION

4.1. Ge9metrical parameters
·The micrographical imaging investigation revealed a co'ritact region between fiber and electrode. The contact
angle is observed to be directly proportional to the pressur~ applied during manufacturing and to the electrode
thickness. The investigated AFC showed a main value of 63.10°, whereas the single values are sensitive to the
sequence of fiber diameters, as emphasized by the relatively high standard deviation of 20.81%. A fiber with
smaller diameter that the neighbor fibers will have a smaller contact angle to one or both electrodes. The
circular.fiber cross section presents a main diameter of 256.6µm with a standard deviation of 1.46%. The main
center-to-center fiber spacing is 291.5µm with a standard deviation of 5.17%.

I Geometrical parameter I Main value I Standard Deviation CV%

d Fiber diameter (µm) 256.6 3.75 1.46
b Fiber spacing (µm) 291.5 15.06 5.17
<p Contact angle (0 ) 63.1 13.13 20.81
p Electrode spacing (µm) 900 - -
w Electrode width (µm) 200 - -
Table 2. Geometrical Parameters. Fiber diameter d, fiber spacing b and contact angle cp were investigated using the
micrographical imaging technology. Values for electrode spa~ing p and electrode width w refer to the electrode supplier.

4.2. Hi'gh field response of PZT' fibers

Butterfly loops were measured for the used piezoelectric ceramic fiber. Figure 4 (a) shows a quite symmetric
curve with a developed strain of approximately 3500ppm. The coercitive electric field lies around lkV/mm.
These results show very good agreement with the literature 10 .

82 Proc. of SPIE Vol. 5390

 4000 3500
3500 3000
3000 2500
I Q.
2500 I
Q.
2000
-;; 2000 ';;' 1500
] 1500 ] 1000
Ul Ul
1000 500
500
0 -500
-3 -2 -1 0 2 3 -1 ·0.5 0 0.5 1.5 2 2.5 3
Electric Field (kV /mm) Electric Field (kV /mm)

a) b)

Figure 4. Characterization of a PZT-5A piezoelectric ceramic fiber via DMA device. a) Butterfly loop, electric field
±3kV/mm. b) Work cycle for an electric field ranging from -0.9kV/mm to 3kV/mm.

The measured work cycle shows a peak~to-peak actuation of approximately 3100ppm for an electrical field
ranging from -0.9 kV/mm to 3 kV/mm. The typical strain driven nonlinearity can be recognized in Figure 4
(b).

4.3. FE results for the RVE

The i.s9potential lines in Figure 5 (a) show the potential distribution in the RYE and the negligible contribution
of the electrode area separated from the fiber by the epoxy resin. The direct contact between electrode and fiber
induces high electric field near the electrode edge (see Figure 5 (b)). The resulting strain peak is up to four
times larger than the strain in the. middle of the fiber, where the electric field is uniform. Further, a reduction in
the strain response along .the fiber axis can be observed under the electrode in Figure 5 (d). This. "dead zone"
is generated by the distortion of the electric field under the electrode, as shown in Figure 5 (c).
The predicted AFC behavior is presented in Figure 6. Free strain response versus applied voltage was
computed for discrete substeps. The. clamping effect of the resin and the polyimide foils is reflected in the
narrower hysteresis curve, compared to the fiber work cycle in Figure 4 (b).

4.4. Experimental results and validation

Figure 6 presents· the work cycle measured for the investigated AFC. This presented an electrode spacing p
of 0.9mm and a contact angle of 63.10°. The comparison with results from the nonlinear simulation shows
a good agreement between the predicted free strain response and the measured work cycle. The numerical
model overestimates the peak-to-peak strain by 6.5%. This is mainly due to the uniformly defined piezoelectric
coefficients (see also 5 ). Being computed for the electric field reigning at z = p/2, these are clearly exceeding the
real values in the "dead zone" under the electrode. Hysteresis shape and width .are accurately predicted.

4.5. Parameter influence

4.5.1. Contact angle
The contact area between the electrode and the fiber has a large influence on the AFC's performance. Increasing
the contact angle for a given electrode width allows for a more efficie~t field distribution while limiting the "dead
zone" under the electrode. On the other hand, increasing the electrode width for a given contact angle would lead
to a larger "dead zone" and increase the breakdown risk in the resin matrix. The effective piezoelectric constant
was compared to the theoretically attainable for different contact. angles. Figure 7 shows a large performance
enhancement for increasing contact angles, asymptotically approaching the 90% mark. AFCs manufactured with
different pressures show according contact angles and free strain ·actuation. The experimental results are in good

Proc. of SPIE Vol. 5390 83

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Figure 5. FE results. a) Potential distribution in the RVE with contact between electrode finger and fiber. b) Electric
field distribution in the RVE . Notice the field peak near the electrode edge and the "dead zone" under the electrode
. surface. Far away from the electrodes, a uniform field distribution can be observed. c) Electric field lines in the RVE.
Notice the field distortion under the electrode. d) Strain distribution in the RVE.

agreement with the numerical prediction. Current AFC manufacturing technology is expected to allow contact
angles up to 80'. Trough-the-thickness electrodes under development 11 will completely enclose the fibers, thus
generating a rotationally symmetric electric field.

4.5.2. Electrode spacing

Simulation and experimental results were compared for four AFCs manufactured with different electrode spacings.
The remaining manufacturing parameters are supposed to be unchanged. The contact a,ngle was shown to be
approximately 50'. Larger electrode spacings show an actuation improvement. Again, the numerical model
overestimates the peak-to-peak strain. Both the experimental curves and the numerical results reveal a decreasing
performance enhancement with increasing electrode spacing (see Figure 8). This is due to the decreasing relative
influence of the "dead-zone" under the electrode (w /p-ratio ). These findings are in good agreement with results
presented by different authors in previous work3- 5 .

84 Proc. of SPIE Vol. 5390

 2500

2000

s=-
.:!;1500
c
.......Ill
Ill

Gl 1000
!!
IL.

500

-1 -0.5 0 0.5 1 1.5 2 2.5 3

Electric Field (kV/mm)

Figure 6. Work cycles for an electric field ranging from -1 to 3kV/mm. The numerical prediction slightly overest!mates
the measured free strain response.

.
1.00 i

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r···········i 0 "''''m•oral ~'"'~ ----~

0.40
0 20 40 60 80 100. 120 140 160 180 200
Contact angle ( 0 )

Figure 7. AFC performance versus contact angle between.electrode and fiber. Experimentally investigated configurations
show good agreement With the numerical prediction.

Proc. of SPIE Vol. 5390 85 ·

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-p=1.1mm_elip
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0 0.5 1,5 2 2.5 3 3.5 4

Electric Field (kV/mm)

Figure 8. Work cycles of AFCs manufactured with different electrode spacings. Both experimental and numerical results
predict larger peak-to-peak strains for increasing electrode spacing.

5. CONCLUSIONS
The free strain response behavior of AFCs under high field conditions has been predicted by a nonlinear FE Model.
The rnicrographical imaging technology was chosen for determination of relevant geometrical parameters. This
revealed a direct contact region between electrode fingers and piezoelectric ceramic fibers. Required characteristic
curves for the piezoelectric coefficients have been accurately determined using a novel characterization procedure
for single PZT fibers based on the DMA device~ The numerical simulation accounted for the AFC's geometrical
complexity and gave insight into the .;lectric field and strain distributions. Due to the assumed uniformity of
the piezoelectric coefficients, numerical results slightly overestimate the experimentally determined free strain
response. The typical work cycle has been predicted for AFCs with different electrode configurations, thus
providing a tool for further AFC optimization. Numerical and experimental findings corroborate previously
published results, revealing enhanced actuation performance for increasing electrode spacing to fiber diameter
ratios. Finally, the influence of the contact angle has been investigated, showing interesting potential for further
performance improvements.

APPENDIX A. MATERIAL PARAMETERS

12
According to the supplier , the piezoelectric Iow field properties of the used PZT5Al ceramic powder (also
known as Navy Type II) are:

440pm/V
-d33/2.38 185pm/V
d33 · l.27 560pm/V

Above properties are measured in monolithic wafers (bulk material).

86 . Proc. of SPIE Vol. 5390

 e31 (C/m ) -2.8
e33 (C/m 2) 16.4
eis (C/m 2) 8.4
c:f/c:o 916 c:i/c:o 4
c:f!c:o 830 c:3/eo 4
cf1 (GPa) 120 cn (GPa) 6.52
cf2 (GPa) 75.1 C12 (GPa) 3.98
cf3 (GPa) 75.1 C13 (GPa) 3.98
cf2 (GPa) 120 c22 (GPa) 6.52
cf3 (GPa) 75.1 c23 (GPa) 3.98
cf3 (GPa) 111 C33 (GPa) 6.25
cf4 (GPa) 21 C44 (GPa) 1.27
elf., (GPa) 21 Cfi6 (GPa) 1.27

Table 3. Material Properties for PZT5Al Fibers and Epoxy Resin Araldite LY 564/ Aradur 2954

ACKNOWLEDGMENTS
Support for this research has been provided by a grant from ETH (Zurich) and EMPA (Duebendorf). The
experimental facilities were provided by EN,{PA (Duebendorf). This work is part of the joint project between
EMPA* IFAt and IMEST.

REFERENCES
1. A. A. Bent and N. W. Hagood, "Development of piezoelectric fiber composites for structural actuation,"
in Proc. 34th AIAA/ASME/ASCE/AHS Structures; Structural Dynamics and Materials Conference. AIAA
Paper no. 93-1717, (La ,Jolla, CA), April :).993. .
2. A. A. Bent, Active Fiber Compopifos for St~-uctural Applications. PhD thesis, Massachusetts Institute of
Technology, 1997. .
3. G. A. Rossetti, A. E. Pizzochero, and .A. A. }3ent, "Recent advancP,s in active fiber composites technology,"
in Proc. Jffh IEEE International Symposium on the Application of Ferroelectrics, Vol. 2, pp. 753-757, 2001.
4. A. A. Bent and A. E. Pizzochcro, "Recent advances in active fiber composites for structural control," in
Proc. SPIE Smart Structures and Materials, Industrial and Commercial Applications of Smart Structures
Technologies, SPIE Vol.3991, pp. 244-254, (Newport Beach, CA), March 2000.
5. L . .J. Nelson, C. R. Bowen, R. Stevens, M. Cain, and M. Stewart, "Modelling and measurement of piezoelec-
tric fibres and interdigitated electrodes for the optimisation of piezofibre composites," in Proc. SPIE Smart
Structures and Materials, Active Materials: Behavior and Mechanics, SPIE Vol. 5053, pp. 556-567, (San
Diego, CA), March 2003.
6. B. Castelli and A. Belloli, "Modeling and c;haracterization of active fiber composites," Master's thesis, Centre
of Structure Technologies, Swiss Federal Institute of Technology, 2003 .
. 7. "IEEE standard on piezoelectricity." ANSI/IEEE Std 176-1987, 1987.
8. R. Zehnder, B. Castelli, and A. Belloli, "Novel characterization procedure for single PZT fibers," Tech. Rep.
· IMES 04-035, Centre of Structure Technologies, Swiss Federal Institute of Technology, Februar 2004.
9. X. Kornmann, C. Huber, and A. R. Elsener, "Piezoelectric ceramic fibers for active fiber composites: a com-
parative study," in Proc. SPIE Smart Structures and Materials, Smart Structures and Integrated Systems,
SPIE Vol.5056, pp. 330-337, (San Diego, CA), March 2003.
•www.empa.ch/ plugin/ template/empa/57/
t www.controLethz.. ch
twww.imes.ethz.ch/st/

Proc. of SPIE Vol. 5390 87

 10. L. J. Nelson, C.R. Bowen, R. Stevens, M. Cain, and M. Stewart, "High field behaviour of piezoelectric fibre
composites," in Proc. SPIE Smart Structutes and Materials, Active Materials: Behavior and Mechanics,
SPIE Vol. 5058, pp. 544-555, (San Diego, CA), March 2003.
11. S. Busato and P. Ermanni, "Development and processing of active fiber composites." Accepted TH project
proposal, Swiss Federal Institute of Techrn,>logy.
12, Smart Material Corp., www.smart-material.com.
'

88 Proc. of SPIE Vol. 5390

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