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Bill, R. C.

Publications and source records attributed to Bill, R. C..

At least 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
NASA NTRS1978

Friction and wear of several compressor gas-path seal movements

Rub interaction experiments were conducted on a series of sintered and plasma sprayed compressor gas path seal materials in contact with Ti-6Al-4V blade tip and knife edge rotors. The most rub tolerant materials investigated were sintered Nichrome and plasma sprayed nickel 25 percent graphite. The effectiveness of providing a compliant substrate for dense seal material coatings was also demonstrated. In general, it was observed that rotor wear and high frictional energy generation rates accompanied smearing or surface densification of the materials investigated. The onset of smearing was sensitive to rub interaction parameters and seal geometry. Two complementary models were proposed to account for the smearing trends. One is based on thermal effects, the other on particulate escape effects. They were shown to be consistent with the experimental evidence at hand, and together they predict that smearing, with the onset of high energy rub conditions, is favored when incursion rates (radial motion) are low, incursion depths are high, the seal geometry is of a knife-edge character, and the seal particle size is small.

Bill, R. C.↗
NASA NTRS1978

Fretting wear of iron, nickel, and titanium under varied environmental conditions

Fretting wear experiments were conducted on high purity iron, nickel and titanium in air under conditions of varied humidity and temperature, and in nitrogen. For iron and titanium, maximum fretting occurred at 10 and 30 percent relative humidity respectively. Nickel showed a minimum in fretting wear at about 10 percent relative humidity. With increasing temperature, all three metals initially showed reduced fretting wear, with increasing wear observed as temperatures increased beyond 200-300 C. For titanium, dramatically reduced fretting wear was observed at temperatures above 500 C, relatable to a change in oxidation kinetics. All three metals showed much less fretting wear in N2 with the presence of moisture in N2 having a proportionally stronger effect than in air.

Bill, R. C.↗
NASA NTRS1978

Wear of seal materials used in aircraft propulsion systems

The various types of seal locations in a gas turbine engine are described, and the significance of wear to each type is reviewed. Starting with positive contact shaft seals, existing material selection guidelines are reviewed, and the existing PV (contact pressure X sliding velocity) criteria for selecting seal materials are discussed, along with the theoretical background for these criteria. Examples of wear mechanisms observed to operate in positive contact seals are shown. Design features that can extend the operating capabilities of positive contact seals, including pressure balancing and incorporation of hydrodynamic lift are briefly discussed. It is concluded that, despite the benefits arising from these design features, improved positive contact seal materials from the standpoint of wear, erosion and oxidation resistance will be necessary for further improvements in seal performance and durability, and to meet stringent future challenges.

Bill, R. C.↗
NASA NTRS1978

Development of sprayed ceramic seal systems for turbine gas path sealing

A ceramic seal system is reported that employs plasma-sprayed graded metal/ceramic yttria stabilized zirconium oxide (YSZ). The performance characteristics of several YSZ configurations were determined through rig testing for thermal shock resistance, abradability, and erosion resistance. Results indicate that this type of sealing system offers the potential to meet operating requirements of future gas turbine engines.

Bill, R. C.↗
NASA NTRS1977

Preliminary study of cyclic thermal shock resistance of plasma-sprayed zirconium oxide turbine outer air seal shrouds

Several experimental concepts representing potential high pressure turbine seal material systems were subjected to cyclic thermal shock exposures similar to those that might be encountered under severe engine start-up and shut-down sequences. All of the experimental concepts consisted of plasma-sprayed yttria stabilized ZrO2 on the high temperature side of the blade tip seal shroud. Between the ZrO2 and a cooled, dense metal backing, various intermediate layer concepts intended to mitigate thermal stresses were incorporated. Performance was judged on the basis of the number of thermal shock cycles required to cause loss of seal material through spallation. The most effective approach was to include a low modulus, sintered metal pad between the ZrO2 and the metallic backing. It was also found that reducing the density of the ZrO2 layer significantly improved the performance of specimens with plasma-sprayed metal/ceramic composite intermediate layers.

Bill, R. C.↗
NASA NTRS1977

Fretting of AISI 9310 and selected fretting resistant surface treatments

Fretting wear experiments were conducted with uncoated AISI 9310 mating surfaces, and with combinations incorporating a selected coating to one of the mating surfaces. Wear measurements and SEM observations indicated that surface fatigue, as made evident by spallation and surface crack formation, is an important mechanism in promoting fretting wear to uncoated 9310. Increasing humidity resulted in accelerated fretting, and a very noticeable difference in nature of the fretting debris. Of the coatings evaluated, alumimum bronze with a polyester additive was most effective at reducing wear and minimizing fretting damage to the mating uncoated surface, by means of a self-lubricating film that developed on the fretting surfaces. Chromium plate performed as an effective protective coating, itself resisting fretting and not accelerating damage to the uncoated surface.

Bill, R. C.↗
NASA NTRS1977

Friction and wear of sintered fibermetal abradable seal materials

Three abradable gas-path seal-material systems based on a sintered NiCrAlY fiber metal structure were evaluated under a range of wear conditions representative of those likely to be encountered in various knife-edge seal (labyrinth or shrouded turbine) applications. Conditions leading to undesirable wear of the rotating knife were identified, and a model proposed based on thermal effects arising under different rub conditions. It was found, and predicted by the model, that low incursion (plunge) rates tended to promote smearing of the low-density sintered material with consequent wear to the knife edge. Tradeoff benefits between baseline 19 percent dense material, a similar material of increased density, and a self-lubricating coating applied to the 19 percent dense material were identified on the basis of relative rub tolerance and erosion resistance.

Bill, R. C.↗
NASA NTRS1977

Recrystallization as a controlling process in the wear of some f.c.c. metals

Detailed examination of copper specimens after sliding against 440 C steel in liquid methane at speeds up to 25 m/s and loads of up to 2 kg showed the metal comprising the wear surface to possess a fine cell recrystallized structure. Wear proceeded by the plastic shearing of metal in this near surface region without the occurrence of visible metal transfer. A dynamic balance between the intense shear process at the surface and the nucleation of recrystallized grains was proposed to account for the behavior of the metal at the wear surface. Sliding wear experiments were also conducted on Ag, Cu-10% Al, Cu-10% Sn, Ni and Al. It was found that low wear and the absence of heavy metal transfer were associated with those metals observed to undergo recrystallization nucleation without prior recovery.

Bill, R. C.↗
NASA NTRS1977

Friction and wear of sintered fiber-metal abradable seal materials

Three abradable gas path seal material systems based on a sintered NiCrAlY fibermetal structure were evaluated under a range of wear conditions representative of those likely to be encountered in various knife-edge seal (labyrinth or shrouded turbine) applications. Conditions leading to undesirable wear of the rotating knife were identified and a model was proposed based on thermal effects arising under different rub conditions. It was found, and predicted by the model, that low incursion (plunge) rates tended to promote smearing of the low density sintered material with consequent wear to the knife-edge. Tradeoffs benefits between baseline 19 percent dense material, a similar material of increased density, and a self lubricating coating applied to the 19 percent material were identified based on relative rub tolerance and erosion resistance.

Bill, R. C.↗
NASA NTRS1977

Fretting of AISI 9310 and selected fretting resistant surface treatments

Fretting wear experiments were conducted with uncoated AISI 9310 mating surfaces, and with combinations incorporating a selected coating to one of the mating surfaces. Wear measurements and SEM observations indicated that surface fatigue, as made evident by spallation and surface crack formation, is an important mechanism in promoting fretting wear to uncoated 9310. Increasing humidity resulted in accelerated fretting, and a very noticeable difference in nature of the fretting debris. Of the coatings evaluated, aluminum bronze with a polyester additive was most effective at reducing wear and minimizing fretting damage to the mating uncoated surface, by means of a selflubricating film that developed on the fretting surfaces. Chromium plate performed as an effective protective coating, itself resisting fretting and not accelerating damage to the uncoated surface.

Bill, R. C.↗
NASA NTRS1976

Selected fretting-wear-resistant coatings for titanium - 6-percent-aluminum - 4-percent-vanadium alloy

A titanium - 6-percent-aluminum - 4-percent-vanadium alloy (Ti-6Al-4V) was subjected to fretting-wear exposures against uncoated Ti-6Al-4V as a baseline and against various coatings and surface treatments applied to Ti-6Al-4V. The coatings evaluated included plasma-sprayed tungsten carbide with 12 percent cobalt, aluminum oxide with 13 percent titanium oxide, chromium oxide, and aluminum bronze with 10 percent aromatic polyester; polymer-bonded polyimide, polyimide with graphite fluoride, polyimide with molybdenum disulfide (MoS2), and methyl phenyl silicone bonded MoS2, preoxidation surface treatment, a nitride surface treatment, and a sputtered MoS2 coating. Results of wear measurements on both the coated and uncoated surfaces after 300,000 fretting cycles indicated that the polyimide coating was the most wear resistant and caused the least wear to the uncoated mating surface.

Bill, R. C.↗
NASA NTRS1975

Fretting of titanium at temperatures to 650 C in air

Fretting wear experiments were conducted on high-purity titanium at temperatures up to 650 C. Results indicate that up to about 500 C, the fretting wear increases with temperature. A further increase in the temperature up to 650 C results in decreasing fretting wear. This change in trend of fretting wear with temperature is shown to be associated with a change in oxidation rate. Additional experiments at 650 C showed a transmission from a low rate of fretting wear to a higher rate occurred after exposure to a number of fretting cycles; the number of cycles required to cause this transition was dependent on the normal load. Scanning electron microscopy studies revealed that this transition was marked by cracking and disruption of the surface oxide film. A model was proposed that coupled the oxidation rate kinetics of titanium at 650 C with the occurrence of wear at the surface of the oxide film.

Bill, R. C.↗
NASA NTRS1975

Friction and wear of carbon-graphite materials for high energy brakes

Caliper-type brakes simulation experiments were conducted on seven different carbon-graphite material formulations against a steel disk material and against a carbon-graphite disk material. The effects of binder level, boron carbide (B4C) additions, graphite fiber additions, and graphite cloth reinforcement on friction and wear behavior were investigated. Reductions in binder level and additions of B4C each resulted in increased wear. The wear rate was not affected by the addition of graphite fibers. Transition to severe wear and high friction was observed in the case of graphite-cloth-reinforced carbon sliding against a disk of similar composition. This transition was related to the disruption of a continuous graphite shear film that must form on the sliding surfaces if low wear is to occur. The exposure of the fiber structure of the cloth constituent is believed to play a role in the shear film disruption.

Bill, R. C.↗
NASA NTRS1975

Fretting in aircraft turbine engines

The problems created by fretting in turbine engines are discussed. The areas of greatest wear identified with the fan, compressor, and turbine blade mountings being the most critical items. Various methods for reducing or eliminating fretting in a turbine engine are described. Vacuum deposition of coatings by sputtering and ion plating are recommended as an economic method of applying thin films to inhibit fretting.

Johnson, R. L.↗
NASA NTRS1974

Surface recrystallization theory of the wear of copper in liquid methane

Copper was subjected to sliding against 440C in liquid methane. The normal load range was from 1/4 to 2 kilograms, and the sliding velocity range was from 3.1 to 25 meters per second. Over this range of experimental parameters, the wear rate of the copper rider was found to be proportional to the sliding velocity squared and to the normal load. Transmission electron microscopy was used to study the dislocation structure in the copper very near the wear scar surface. It was found that near the wear scar surface, the microstructure was characterized by a fine-cell recrystallized zone in which individual dislocations could be distinguished in the cell walls. The interiors of the cells, about 0.5 micrometer in diameter, were nearly dislocation free. Below the recrystallized layer was a zone that was intensely cold worked by the friction process. With increasing depth, this intensely cold worked zone gradually became indistinguishable from the partially cold worked bulk of the copper, representative of the initial condition of the material.

Bill, R. C.↗
NASA NTRS1974

Fretting in aircraft turbine engines

Fretting usually produces both polished and pitted areas. Fretting occurs in connection with the relative motion between contacting surface elements. Particular attention is given to fretting in seals, splines, fans, compressors, and turbine blades. Recommended approaches to mitigate fretting problems include a reduction of the adhesion between two surfaces. Approaches for doing this may include the development of alloys which spontaneously generate a self-healing surface film, different in composition from the bulk alloy. Other fundamental adhesion studies have shown that surface crystal structure and crystallographic orientation significantly affect the adhesion properties of alloys.

Johnson, R. L.↗
NASA NTRS1974

Some metal-graphite and metal-ceramic composites for use as high energy brake lining materials

Materials were studied as candidates for development as potential new aircraft brake lining materials. These families were (1) copper-graphite composites; (2) nickel-graphite composites; (3) copper - rare-earth-oxide (gadolinium oxide (Gd2O3) or lanthanum oxide (La2O3)) composites and copper - rare-earth-oxide (La2O3) - rare-earth-fluoride (lanthanum fluoride (LaF3)) composites; (4) nickel - rare-earth-oxide composites and nickel - rare-earth-oxide - rare-earth-fluoride composites. For comparison purposes, a currently used metal-ceramic composite was also studied. Results showed that the nickel-Gd2O3 and nickel-La2O3-LaF3 composites were comparable or superior in friction and wear performance to the currently used composite and therefore deserve to be considered for further development.

Bill, R. C.↗