Engineering topics
Publications and source records attributed to Lauer, J. L..
Pyrolytic carbon proves useful as solid lubricant in ceramic bearings in advanced gas-turbine engines, where high temperatures destroy liquid lubricants. Ethylene gas made to flow past bearings and pyrolized to replenish carbon lubricant particles.
Sliding tests with a pin-on-disc tribometer and both sliding and rolling tests with a modified four-ball tester at bulk temperatures of about 500 C and contact pressures of about 2.2 GPa have demonstrated up to 80% reductions of friction and wear with silicon nitride surfaces when a stream of ethylene is directed into the conjunction region. The effects are even more pronounced when the ethylene is prenucleated by a flow over a coil of nichrome wire electrically heated to about 800 C and located about 30 cm upstream of the exit nozzle. Steel and Ni-plated steel are lubricated by this method even more efficiently at lower temperatures.
The relationship of fuel stability to fuel composition and the development of mechanisms for deposit formation were investigated. Fuel deposits reduce heat transfer efficiency and increase resistance to fuel flow and are highly detrimental to aircraft performance. Infrared emission Fourier transform spectroscopy was chosen as the primary method of analysis because it was sensitive enough to be used in-situ on tiny patches of monolayers or of only a few molecular layers of deposits which generally proved completely insoluble in any nondestructive solvents. Deposits of four base fuels were compared; dodecane, a dodecane/tetralin blend, commercial Jet A fuel, and a broadened-properties jet fuel particularly rich in polynuclear aromatics. Every fuel in turn was provided with and without small additions of such additives as thiophene, furan, pyrrole, and copper and iron naphthenates.
An infrared Fourier microemission spectrophotometer is used to obtain spectra (wavenumber range, 630 to 1230 0.1 cm) from microgram quantities of thioether lubricant samples deposited on aluminum foil. Infrared bands in the spectra are reproducible and could be identified as originating from aromatic species (1,3-disubstituted benzenes). Spectra from all samples (neat and formulated, used and unused) are very similar. Additives (an acid and a phosphinate) present in low concentration (0.10 percent) in the formulated fluid are not detected. This instrument appears to be a viable tool in helping to identify lubricant components separated by liquid chromatography.
An ester lubricant base oil containing one or more standard additives to protect against wear, corrosion, and oxidation was used in an experimental ball/plate elastohydrodynamic contact under load and speed conditions such as to induce scuffing failure in short times. Both the ball and the plate were of identically treated M-50 steel. After various periods of operating time the wear track on the plate was examined with an interference microscope of plus or minus 30 A depth resolution and sometimes also with a scanning ellipsometer and an Auger spectrometer. The optically deduced surface profiles varied with wavelength, indicating the presence of surface coatings, which were confirmed by the other instruments. As scuffing was approached, a thin (approximately A) oxide layer and a carbide layer formed in the wear track in particular when tricresylphosphate antiwear additive was present in the lubricant. The rates of the formation of these layers and their reactivity toward dilute alcoholic HCl depended strongly on the lubricant and additives. Based on these results suggestions for improved formulations and a test method for bearing reliability could be proposed.
A scanning ellipsometer with high spatial resolution was used to analyze wear tracks generated on M-50 surfaces operated in several lubricant formulations. These formulations included a pure ester base stock of trimethyol propane triheptanoate with additives of either benzotriazole (BTZ), dioctyldiphenylamine (DODPA), or tricresylphosphate (TCP). Results indicated that BTZ and TCP produced patchy oxide surface films consisting mainly of Fe304. DOPDA produced a much more uniform oxide film. These findings may explain the tendency of lubricant formulations containing TCP to scuff more readily than those containing only antioxidants.
Ellipsometric analyses of wear tracks in berings of M-50 steel were carried out after operation under severe conditions with different lubricant additives. The base lubricant was a synthetic ester. It was found that the surface and wear additives benzotirazole and tricresylyphosphate produced very patchy oxide layers. Dioctyldiphenylamine, a common antioxidant, on the other hand produced smoother films. The analyses were performed with a specially designed and constructed ellipsometer of very high (20 micron) spatial resolution. The results are consistent with data obtained by Auger electron spectroscopy.
The composition and surface profiles of M-50 steel surfaces were measured after operation at high loads in a bearing contact simulator. An ester lubricant (trimethyolpropane triheptanoate) was used with and without various additives. Optical profiles were obtained + or - to 30 depth resolution with a phase-locked interference microscope in 10 micron diameter areas within and outside the wear tracks. Optical constants and surface film thickness were measured in the same areas with an electronic scanning ellipsometer. Film composition was measured with a scanning Auger electron spectrometer. It is concluded that metal oxide formation is accelerated within the wear tracks.
A ball-on-plate (both consisting of hardened M-50 steel) sliding elastohydrodynamic contact was run with trimethylolpropane triheptanoate (TMPTH) with and without tricresyl phosphate (TCP). The contact area of the plate was optically profiled with a phase-locked interference microscope (PLIM) both before and after exposure to alcoholic hydrochloric acid. As scuffing was approached, the profile within the contact region changed more rapidly after the acid treatment; after scuffing, it assumed a constant high value. A metallurgical phase found in the scuff mark was apparently responsible for the high reactivity. The microscopic profile changes (sensitivity, + or - 3 nm (+ or - A) in depth) involved primarily the small asperities (radius, 3 microns); the larger ones were unaffected. Soaking the steel in TCP smoothed the fine structure of the surface profile but increased its reactivity toward alcoholic hydrochloric acid before sliding was started. Thus it would appear that PLIM examination could be used for screening potentially scuff-resistant materials.
An electronic optical laser interferometer capable of resolving depth differences of as low as 30 A and planar displacements of 6000 A was constructed to examine surface profiles of bearing surfaces without physical contact. Topological chemical reactivity was determined by applying a drop of dilute alcoholic hydrochloric acid and measuring the profile of the solid surface before and after application of this probe. Scuffed bearing surfaces reacted much faster than virgin ones but that bearing surfaces exposed to lubricants containing an organic chloride reacted much more slowly. The reactivity of stainless steel plates, heated in a nitrogen atmosphere to different temperatures, were examined later at ambient temperature. The change of surface contour as a result of the probe reaction followed Arrhenius-type relation with respect to heat treatment temperature. The contact area of the plate of a ball/plate sliding elastohydrodynamic contact run on trimethylopropane triheptanoate with or without additives was optically profiled periodically. As scuffing was approached, the change of profile within the contact region changed much more rapidly by the acid probe and assumed a constant high value after scuffing. A nonetching metallurgical phase was found in the scuff mark, which was apparently responsible for the high reactivity.
Deposits laid down in patches on metal strips in a high pressure/high temperature fuel system simulator operated with aerated fuel at varying flow rates were analyzed by emission FTIR in terms of functional groups. Significant differences were found in the spectra and amounts of deposits derived from fuels to which small concentrations of oxygen-, nitrogen-, or sulfur-containing heterocyclics or metal naphthenates were added. The spectra of deposits generated on strips by heating fuels and air in a closed container were very different from those of the flowing fluid deposits. One such closed-container dodecane deposit on silver gave a strong surface-enhanced Raman spectrum.
An ester lubricant base oil containing one or more standard additives to protect against wear, corrosion, and oxidation was used in an experimental ball/plate elastohydrodynamic contact under load and speed conditions such as to induce scuffing failure in short times. Both the ball and the plate were of identically treated M-50 steel. After various periods of operating time the wear track on the plate was examined with an interference microscope of plus or minus 30 A depth resolution and sometimes also with a scanning ellipsometer and an Auger spectrometer. The optically deduced surface profiles varied with wavelength, indicating the presence of surface coatings, which were confirmed by the other instruments. As scuffing was approached, a thin (approximately A) oxide layer and a carbide layer formed in the wear track in particular when tricresylphosphate antiwear additive was present in the lubricant. The rates of the formation of these layers and their reactivity toward dilute alcholic HCl depended strongly on the lubricant and additives. Based on these results suggestions for improved formulations and a test method for bearing reliability could be proposed.
Solid and liquid thin films were analyzed by infrared emission Fourier microspectrophotometry. The apparatus used is a commercial absorption instrument modified to an emission instrument, comprising a rotating polarizing device, a miniature blackbody temperature reference adjustable in temperature and radiant flux and a microscope lens with a high numerical aperture in the entrance system for increased sensitivity and resolution. Studies of lubricant behavior in a simulated ball bearing showed the alignment of the fluid molecules in the Hertzian area. Polyphenyl ether plus 1% 1,1,2-trichloroethane (TCE) required lower shear rates for the same degree of alignment than without TCE. The experiment was run with 440 C stainless steel balls coated with TiN, a chemically inert material. In both cases, the alignment was strongly influenced by the presence of TCE. The results showed (1) the dependence of alignment of fluid molecules on flow and not on adsorption at metallic surfaces, (2) phase separation between lubricant and additive under high pressure which results in two phase flow and (3) reduction in traction of torque transmitting (traction) fluids.
A ball-on-plate (both consisting of hardened M-50 steel) sliding elastohydrodynamic contact was run with trimethylolpropane triheptanoate (TMPTH) with and without tricresyl phosphate (TCP). The contact area of the plate was optically profiled with a phase-locked interference microscope (PLIM) both before and after exposure to alcoholic hydrochloric acid. As scuffing was approached, the profile within the contact region changed more rapidly after the acid treatment; after scuffing, it assumed a constant high value. A metallurgical phase found in the scuff mark was apparently responsible for the high reactivity. The microscopic profile changes (sensitivity, + or - 3 nm (+ or - A) in depth) involved primarily the small asperities (radius, 3 microns); the larger ones were unaffected. Soaking the steel in TCP smoothed the fine structure of the surface profile but increased its reactivity toward alcoholic hydrochloric acid before sliding was started. Thus it would appear that PLIM examination could be used for screening potentially scuff-resistant materials.
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Infrared emission spectra and related measurements were obtained from an operating ball/plate EHD sliding contact under a variety of operating conditions. In order to be able to compare the effect of the ball surface, some of the steel balls were coated with a thin layer of titanium nitride (TiN) by vapor deposition. Polyphenyl ether (5P4E) was used as the lubricant and 1 percent of 1,1,2-trichloroethane TCE) as an additive with a high affinity for steel but a low affinity for TiN. TiN is chemically inert, but its thermal conductivity is lower than that of steel. Therefore, the overall temperatures with TiN-coated balls were higher. Nevertheless, no scuffng was observed with the coated balls under conditions giving rise to scuffing with the uncoated balls. Tractions were lower with the TiN-coated balls and with the steel balls when TCE was added to the 5P4E. These findings were found to be inversely related to the degree of polarization of the spectral emission bands. The intensity and the dichroism of these bands were related to shear rates and inlet conditions of the EHD contact.
An electronic optical laser interferometer capable of resolving depth differences of as low as 30 A and planar displacements of 6000 A was constructed for the examination of surface profiles of bearing surfaces without physical contact. This instrument was used to determine topological chemical reactivity by applying a drop of dilute alcoholic hydrochloric acid and measuring the profile of the solid surface before and after application of this probe. It was found that scuffed bearing surfaces reacted much faster than virgin ones but that bearing surfaces exposed to lubricants containing an organic chloride reacted much more slowly. In a separate series of experiments, a number of stainless steel plates were heated in a nitrogen atmosphere to different temperatures and their reactivity examined later at ambient temperature. The change of surface contour as a result of the probe reaction was found to follow an Arrhenius-type relation with respect to heat treatment temperature. This result could have implications on the scuffing mechanism.
Infrared emission spectra and related measurements were obtained from an operating ball/plate elastohydrodynamic (EHD) sliding contact under a variety of operating conditions. In order to be able to compare the effect of the ball surface, some of the balls were coated with a thin layer of titanium nitride (TiN) by vapor deposition. Polyphenyl ether (5P4E) was used as lubricant and 1 percent of 1,1,2-trichloroethane (TCE) as a surface-probing additive. TiN is chemically inert and its thermal conductivity is lower than that of steel. Therefore, the overall temperatures with TiN coated balls were higher. Nevertheless, no scuffing was observed with the coated balls under conditions giving rise to scuffing with the uncoated balls. Tractions were lower with the TiN coated balls and always when TCE was added to the 5P4E. These findings were found to be inversely related to the degree of polarization of the spectral emission bands. The intensity and the dichrosim of these bands were related to shear rates and inlet conditions of the EHD contact.