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At least 181 records · Page 10
All sourcesNASA NTRSDOE OSTI
NASA NTRS1982

Bearing fatigue investigation 3

The operating characteristics of large diameter rolling-element bearings in the ultra high speed regimes expected in advanced turbine engines for high performance aircraft were investigated. A high temperature lubricant, DuPont Krytox 143 AC, was evaluated at bearing speeds to 3 million DN. Compared to the results of earlier, similar tests using a MIL-L-23699 (Type II) lubricant, bearings lubricated with the high density Krytox fluid showed significantly higher power requirements. Additionally, short bearing lives were observed when this fluid was used with AISI M50 bearings in an air atmosphere. The primary mode of failure was corrosion initiated surface distress (fatigue) on the raceways. The potential of a case-carburized bearing to sustain a combination of high-tangential and hertzian stresses without experiencing race fracture was also investigated. Limited full scale bearing tests of a 120 mm bore ball bearing at a speed of 25,000 rpm (3 million DN) indicated that a carburized material could sustain spalling fatigue without subsequent propagation to fracture. Planned life tests of the carburized material had to be aborted, however, because of apparent processing-induced material defects.

Nahm, A. H.↗
NASA NTRS1972

Recent technology advances in the NASA-Lewis Research Center Brayton program

A review of the progress and milestones passed in the Brayton program is presented. The 2-to-15 kWe power system was successfully operated in a vacuum with a space-type radiator. Gas loop and electrical subsystem endurance tests have continued to demonstrate long-term operation with one rotating unit surpassing 10,000 hours of failure-free operation. Simplified gas-bearing designs for the rotating unit are being evaluated. Fabrication of an improved design of heat exchanger is nearing completion, and a study of more advanced heat exchanger technology is being conducted. A study was completed to investigate the applicability of Brayton technology applied to a lower power level (0.5 to 2.5 kWe) and showed potentially very attractive performance, simplicity, and low cost for a system in this power range.

Vernon, R.↗
NASA NTRS1972

Recent technology advances in the NASA-Lewis Research Center Brayton program.

A review of the progress and milestones passed in the Brayton program during the past year is presented. The 2-to-15 kWe power system was successfully operated in a vacuum with a space-type radiator. Gas loop and electrical subsystem endurance tests have continued to demonstrate long-term operation with one rotating unit surpassing 10,000 hours of failure-free operation. Simplified gas-bearing designs for the rotating unit are being evaluated. Fabrication of an improved design of heat exchanger is nearing completion, and a study of more advanced heat exchanger technology is being conducted.

Vernon, R.↗
NASA NTRS1983

Mode 2 fatigue crack growth specimen development

A Mode II test specimen was developed which has potential application in understanding phemonena associated with mixed mode fatigue failures in high performance aircraft engine bearing races. The attributes of the specimen are: it contains one single ended notch, which simplifiers data gathering and reduction; the fatigue crack grous in-line with the direction of load application; a single axis test machine is sufficient to perform testing; and the Mode I component is vanishingly small.

Buzzard, R. J.↗
NASA NTRS1986

Mode II fatigue crack growth specimen development

A Mode II test specimen was developed which has potential application in understanding phemonena associated with mixed mode fatigue failures in high performance aircraft engine bearing races. The attributes of the specimen are: it contains one single ended notch, which simplifies data gathering and reduction; the fatigue crack grows in-line with the direction of load application; a single axis test machine is sufficient to perform testing; and the Mode I component is vanishingly small.

Buzzard, R. J.↗
NASA NTRS1987

Carbide/Fluoride/Silver Self-Lubricating Composite

Bearing coatings survive at operating temperatures up to 870 degrees C. PS200 composite self-lubricating coating for bearing applications operating at temperatures above failure points of traditional solid lubricants. Excellent friction and wear performance in oxidizing atmospheres up to 1,600 degrees F and reducing atmospheres up to 1,400 degrees F. Performance needed for development of advanced heat engines as adiabatic diesel and Stirling engine.

Sliney, Harold E.↗
NASA NTRS1996

Feasibility Study of a Rotorcraft Health and Usage Monitoring System (HUMS): Results of Operator's Evaluation

The objective was to evaluate the feasibility of a state-of-the-art health and usage monitoring system (HUMS) to provide monitoring of critical mechanical systems on the helicopter, including motors, drive train, engines, and life-limited components. The implementation of HUMS and cost integration with current maintenance procedures was assessed from the operator's viewpoint in order to achieve expected benefits from these systems, such as enhanced safety, reduced maintenance cost, and increased availability. An operational HUMS that was installed and operated under an independent flight trial program was used as a basis for this study. The HUMS equipment and software were commercially available. Based on the results of the feasibility study, the HUMS used in the flight trial program generally demonstrated a high level of reliability in monitoring the rotor system, engines, drive train, and life-limited components. The system acted as a sentinel to warn of impending failures. A worn tail rotor pitch bearing was detected by HUMS, which had the capability for self testing to diagnose system and sensor faults. Examples of potential payback to the operator with HUMS were identified, including reduced insurance cost through enhanced safety, lower operating costs derived from maintenance credits, increased aircraft availability, and improved operating efficiency. The interfacing of HUMS with current operational procedures was assessed to require only minimal revisions to the operator's maintenance manuals. Finally the success in realizing the potential benefits from HUMS technology was found to depend on the operator, helicopter manufacturer, regulator (FAA), and HUMS supplier working together.

Romero, Raylund↗
NASA NTRS2015

Solar Alpha Rotary Joint (SARJ) Lubrication Interval Test and Evaluation (LITE). Post-Test Grease Analysis

The Solar Alpha Rotary Joint (SARJ) is a mechanism of the International Space Station (ISS) that orients the solar power generating arrays toward the sun as the ISS orbits our planet. The orientation with the sun must be maintained to fully charge the ISS batteries and maintain all the other ISS electrical systems operating properly. In 2007, just a few months after full deployment, the starboard SARJ developed anomalies that warranted a full investigation including ISS Extravehicular Activity (EVA). The EVA uncovered unexpected debris that was due to degradation of a nitride layer on the SARJ bearing race. ISS personnel identified the failure root-cause and applied an aerospace grease to lubricate the area associated with the anomaly. The corrective action allowed the starboard SARJ to continue operating within the specified engineering parameters. The SARJ LITE (Lubrication Interval Test and Evaluation) program was initiated by NASA, Lockheed Martin, and Boeing to simulate the operation of the ISS SARJ for an extended time. The hardware was designed to test and evaluate the exact material components used aboard the ISS SARJ, but in a controlled area where engineers could continuously monitor the performance. After running the SARJ LITE test for an equivalent of 36+ years of continuous use, the test was opened to evaluate the metallography and lubrication. We have sampled the SARJ LITE rollers and plate to fully assess the grease used for lubrication. Chemical and thermal analysis of these samples has generated information that has allowed us to assess the location, migration, and current condition of the grease. The collective information will be key toward understanding and circumventing any performance deviations involving the ISS SARJ in the years to come.

Golden, Johnny L.↗
NASA NTRSDate not supplied

Tribological Prospects and Progress for NiTi Bearings for Aerospace Applications

Rolling element and sliding bearings made from dimensionally stable, nickel-rich NiTi alloys have been successfully manufactured, tested and applied in several different aerospace applications. In this presentation, the development history and material properties of NiTi alloys is reviewed and its behavior in sliding and rolling contacts is examined. Key material characteristics such as superelasticity and fracture toughness and their effects on bearing applications are considered. With proper application engineering, it is shown that NiTi bearings can resolve longstanding and persistent bearing problems related to heavy loads and operation in corrosive and debris contaminated environments.

Bearings↗
NASA NTRS1987

Bearing-bypass loading on bolted composite joints

The effects of simultaneous bearing and bypass loading on a graphite-epoxy (T300/5208) laminate were investigated. Onset damage and ultimate strengths were determined for each test case. A finite element stress analysis was conducted for each test case. The computed local stresses were used with appropriate failure criteria to analyze the observed failure modes and strengths. An unexpected interaction of the effect of the bypass and bearing loads was found for the onset of compression reacted bearing damage. The interaction was caused by a decrease in the bolt-hole contact arc and a corresponding increase in the severity of the bearing loads. The amount of bolt-hole contact had a significant effect on local stresses and, thus, on the calculated damage-onset and ultimate strengths. An offset-compression failure mode was identified for laminate failure under compression bearing-bypass loading.

Crews, J. H., Jr.↗
NASA NTRS1981

Endurance tests with large-bore tapered-roller bearings to 2.2 million DN

Endurance life tests were run with standard design and optimized high-speed design 120.65-mm-(4.750-in.-) bore tapered-roller bearings at shaft speeds of 12,500 and 18,500 rpm, respectively. Standard design bearings of vacuum melted AISI 4320 and CBS-1000M, and high-speed design bearings of CBS-1000M and through-hardened AISI M-50 were run under heavy combined radial and thrust load until fatigue failure or until a preset cutoff time of 1100 hours was reached. Standard design bearings made from CBS 1000M material ran to a 10 percent life approximately six times rated catalog life. Twelve identical bearings of AISI 4320 material ran to ten times rated catalog life without failure. Cracking and fracture of the cones of AISI M-50 high-speed design bearings occurred at 18,500 rpm due to high tensile hoop stresses. Four CBS 1000M high-speed design bearings ran to twenty-four times rated catalog life without any spalling, cracking or fracture failures.

Parker, R. J.↗
NASA NTRS1984

High pressure oxygen turbopump bearing cage stability analyses

The low service life of the high pressure oxygen turbopump (HPOTP) bearings used in the space shuttle main engine was examined by use of the Battelle "BASDAP' bearing computer stability model. The dynamic instability of the bearing cage resulted in excessive wear and eventual failure of the unit. By maintaining a cage/race clearance of no more than 0.25 millimeters (0.010 inches), ball/pocket clearance of no less than 0.54 millimeters (0.025 inches), dynamic balancing of the cages, and maintaining adequate lubricant films between the balls and races, cage instability and subsequent bearing degradation can be reduced.

Merriman, T. L.↗
NASA NTRS2013

Conical Seat Shut-Off Valve

A moveable valve for controlling flow of a pressurized working fluid was designed. This valve consists of a hollow, moveable floating piston pressed against a stationary solid seat, and can use the working fluid to seal the valve. This open/closed, novel valve is able to use metal-to-metal seats, without requiring seat sliding action; therefore there are no associated damaging effects. During use, existing standard high-pressure ball valve seats tend to become damaged during rotation of the ball. Additionally, forces acting on the ball and stem create large amounts of friction. The combination of these effects can lead to system failure. In an attempt to reduce damaging effects and seat failures, soft seats in the ball valve have been eliminated; however, the sliding action of the ball across the highly loaded seat still tends to scratch the seat, causing failure. Also, in order to operate, ball valves require the use of large actuators. Positioning the metal-to-metal seats requires more loading, which tends to increase the size of the required actuator, and can also lead to other failures in other areas such as the stem and bearing mechanisms, thus increasing cost and maintenance. This novel non-sliding seat surface valve allows metal-to-metal seats without the damaging effects that can lead to failure, and enables large seating forces without damaging the valve. Additionally, this valve design, even when used with large, high-pressure applications, does not require large conventional valve actuators and the valve stem itself is eliminated. Actuation is achieved with the use of a small, simple solenoid valve. This design also eliminates the need for many seals used with existing ball valve and globe valve designs, which commonly cause failure, too. This, coupled with the elimination of the valve stem and conventional valve actuator, improves valve reliability and seat life. Other mechanical liftoff seats have been designed; however, they have only resulted in increased cost, and incurred other reliability issues. With this novel design, the seat is lifted by simply removing the working fluid pressure that presses it against the seat and no external force is required. By eliminating variables associated with existing ball and globe configurations that can have damaging effects upon a valve, this novel design reduces downtime in rocket engine test schedules and maintenance costs.

Farner, Bruce↗
DOE OSTI2022

MAGNETICALLY SUSPENDED CANNED ROTOR PUMPS FOR THE INTEGRAL MOLTEN SALT REACTOR

This project developed a molten salt pump design for small modular reactors, concentrated solar, and Gen IV nuclear reactors with a magnetically levitated rotor that can operate at temperatures of up to 700 °C. This eliminates the need for rotating seals and roller element bearings which require maintenance and are prone to failure. The pump design is also more compact than existing molten salt pump designs which require long shafts to thermally isolate the electric motor. The aims of the project are to: 1) design and test the molten salt pump, 2) develop and test a high temperature position sensor needed for magnetic bearing control, and 3) develop and test high temperature coil fabrication methods for electric motor and magnetic bearing fabrication. To develop the high temperature coils, conductor materials were analyzed for oxidation, diffusion, cladding, and resistivity. Of the candidate conductor materials that met the requirements, silver was chosen. The long-term impact of radiation on silver resistivity was analyzed by developing a model of a generic molten salt fast reactor to model the conductor irradiation in worst case scenarios. The analysis showed that increased resistivity due to transmutation of silver decreases exponentially with the reactor reflector thickness. Different electrical insulation materials were tested and the final high temperature coils developed were able to withstand conductor to ground voltages up to 1800 V before insulation breakdown. Magnetic bearings require high-precision high-speed measurements of the rotor position to operate. Current commercial position sensors can only operate up to 550 °C so a novel position sensor was developed that can operate up to 800 °C. These sensors were also designed to measure the position of the metallic rotor through a thin metallic corrosion barrier that protects that coils, insulation, and magnetic cores so that the salt containment barrier does not have any penetrations. The high-temperature sensor was tested and had comparable performance to commercially available inductive position sensors. The sensor design and signal processing has led to several invention disclosures. The magnetically levitated molten salt pump design was completed and analyzed. The chloride salt test loop at Oak Ridge National Laboratory was chosen to test the pump and the pump hydraulics and power were designed for the test loop flow and pressure requirements. Classes of motor designs that do not utilize permanent magnetic were considered for the high-temperature motor. After extensive analysis of their performance, a synchronous reluctance motor was chosen for the pump. The design was refined and analyzed to optimize performance. The magnetic bearings were designed to meet the force and frequency requirements necessary to levitate the rotor and reject disturbances from rotor imbalance, motor forces, and hydraulic forces. Compliant mounts for the position sensors were designed that would not damage the ceramic sensor components and maintain sensor alignment over a wide temperature range. A thermal hydraulic analysis of the molten salt coolant flow used to cool the rotor and stator was performed to ensure that the maximum temperature in the rotor and stator will not exceed 725 °C. The corrosion barrier and casing were designed to maintain the salt fluid boundary by using compliant features to absorb large expansion mismatches due to different coefficients of thermal expansion (CTE). Finally, the salt drain and fill systems were designed along with the pump support structure, integration with the test loop, and thermal insulation and heating. Corrosion barrier fabrication experiments were performed to assess using laser cladding to apply a sub-millimeter corrosion barrier to the surface of a Fe-Co-V magnetic core material. The cladding method showed minimal mixing between materials at their interface and withstood temperature cycling without damage to the cladding. The technology commercialization is focused on the high-temperature position sensors and there has been significant interest from the nuclear industry in utilizing these sensors along with some interest from the aerospace industry. The project also led to a research collaboration with a fusion energy industrial partner to study barriers to scaling the pump design from the kW size to the MW size. This research collaboration will also study methods to create high-temperature coils that have conductor to ground breakdown voltages above 5 kV. The successful development of high-temperature electromagnetic coils and high-temperature position sensors greatly increases the temperature limits for electromagnetic devices that don’t rely on permanent magnets. This includes electric motors, magnetic bearings, linear actuators, rotary position and velocity sensing, actuated valves, and generators to name a few. This will fill a current need in molten salt reactors, concentrated solar, and fusion energy for these critical peripheral devices needed for practical reactor designs that do not currently have commercial solutions.

Hines, J Wesley↗
NASA NTRS1983

Mechanically fastened joints in woven fabric composites

Strength analysis for composite bolted joints involves the mating of a stress analysis with an appropriate mode specific failure criterion for each of the primary failure modes. The stress analysis and failure criteria are independent of each other and can be manipulated separately in order to optimize the strength analysis package formed by their coupling. Material properties tests were conducted on rubber toughened graphite-epoxy material to measure the basic strength and stiffness in the warp and fill directions and in shear. Test matrices are summarized for investigations of laminate configuration, stacking sequence, fastener diameter, edge distance, fastener half spacing, laminate thickness, and fastener torque. A three dimensional finite element analysis computer program was written and failure criteria for net tension, shearout, and bearing were determined.

Wilson, D. W.↗
NASA NTRS2019

Improved Processing Techniques for Inclusion-Free Steel for Bearing and Mechanical Component Applications

High hardness, high carbide powder metallurgy tools steels such as M62 enable the operation of ball bearings at extremely high load and stress levels. Operation under such conditions increases the potential for rolling contact fatigue failure attributed to ceramic particle inclusions. To address this challenge, industry has sought steel made from ever increasing levels of cleanliness but the results have been uneven owing to the random nature of the occurrence of material flaws. One common approach is to rely upon careful ingot inspections prior to bearing manufacture. By selecting the cleanest portion of an ingot, it is expected that bearings relatively free from material flaws will result. This approach is not always successful because detrimental flaws that exist deep within an ingot can pass inspection undetected potentially causing subsequent failure. Recent efforts to commercialize an intermetallic material, 60NiTi, for rolling element bearings demonstrates a pathway to produce bearing steel that is free from unwanted ceramic particle inclusions. In this paper, the process used to make bearing grade ceramic-free NiTi alloys is described and applied to steelmaking. At its core, the NiTi process differs from steel making in one key aspect. NiTi alloys are made from elementally pure starting materials that are melted, blended and processed in equipment absolutely free from exposure to oxygen and ceramics ensuring a ceramic particle-free product. In contrast, the predominant method to make bearing steel is to employ a successive series of purification steps to reduce contamination levels below required thresholds. This paper describes the processes developed and applied to high carbide tool steel, M62. The resulting material and microstructures are evaluated and compared to M62 prepared by conventional powder metallurgy techniques. It is hoped that the application of materials manufacturing techniques used for fracture sensitive ceramics and intermetallic materials like NiTi can provide a pathway to Ultra-Clean, Ceramic-Inclusion free steels for rolling element bearings and other failure critical applications.

Steel↗
NASA NTRS2003

Radial Clearance Found To Play a Key Role in the Performance of Compliant Foil Air Bearings

Compliant foil air bearings are at the forefront of the Oil-Free turbomachinery revolution, which supports gas turbine engines with hydrodynamic bearings that use air instead of oil as the working fluid. These types of bearings have been around for almost 50 years and have found a home in several commercial applications, such as in air cycle machines, turbocompressors, and microturbines, but are now being aggressively pursued for use in small and midrange aircraft gas turbine engines. Benefits include higher operating speeds and temperatures, lower maintenance costs, and greater reliability. The Oil-Free Turbomachinery team at the NASA Glenn Research Center is working to foster the transition of Oil-Free technology into gas turbine engines by performing in-house experiments on foil air bearings in order to gain a greater insight into their complex operating principles. A research program recently undertaken at Glenn focused on the concept of radial clearance and its influence on bearing performance. The tests were conducted on foil bearings with different radial clearances. As defined for a foil bearing, radial clearance is a measure of the small amount of shaft radial motion that is present from play that exists in the elastic support structure, such as between the top and bump foils and the bump foils and bearing shell (see the drawing). With an insufficient amount of radial clearance, the bearing imparts a high preload on the shaft, which when excessive, can reduce the loadcarrying capability of the bearing. On the other hand, systems using foil bearings with excessive radial clearance may experience rotordynamic instabilities because of low bearing preload. Therefore, without a more thorough understanding of radial clearance, it is difficult to accurately predict the performance of a given bearing design. The test program demonstrated that there is a direct correlation between radial clearance and the performance of foil air bearings. As shown in the graph, an optimum radial clearance exists that will maximize the amount of load that the bearing is capable of supporting. With respect to this optimum, two different performance regimes were observed that are a function of the amount of radial clearance. Tests showed that bearings with radial clearances below the optimum in regime I were susceptible to sudden seizure, a failure mode indicative of thermal runaway caused by high preload. The high preload is in response to an insufficient amount of radial clearance available to accommodate the thermal growth of the bearing and shaft. However, radial clearances greater than the optimum in regime II resulted in low bearing preloads that did not cause any heat-related problems, and the failure mode was due to fluid-film breakdown. In fact, bearings operating with radial clearances twice as much as the optimum suffered a decrease in the maximum load capacity of only about 20 percent. Therefore, special attention has to be given to the range of operating conditions expected in the bearing/shaft system since changes in temperature, centrifugal, and hydrodynamic effects can all affect radial clearance. This enhanced understanding of foil air bearing behavior will greatly aid our efforts to transition Oil-Free technology to future aircraft engines.

Radil, Kevin C.↗
NASA NTRS1977

Life analysis of restored and refurbished bearings

An analysis of the potential life of refurbished and restored bearings was performed. The sensitivity of 10-percent life and mean-time-between-failure to the effects of cumulative fatigue damage and the amount of stressed volume removed in the restoration process were examined. A modified Lundberg-Palmgren theory was used to predict that the expected 10-percent life of a restored bearing, which is dependent on the previous service time and the volume of material removed from the race surfaces, can be between 74 and 100 percent of the new bearing life. Using renewal theory, it is found that the mean time between failure ranged from 90 to 100 percent of that for a new bearing.

Coy, J. J.↗