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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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All sources NASA NTRS DOE OSTI

NASA NTRS2012

Performance of Simple Gas Foil Thrust Bearings in Air

Foil bearings are self-acting hydrodynamics devices used to support high speed rotating machinery. The advantages that they offer to process fluid lubricated machines include: high rotational speed capability, no auxiliary lubrication system, non-contacting high speed operation, and improved damping as compared to rigid hydrodynamic bearings. NASA has had a sporadic research program in this technology for almost 6 decades. Advances in the technology and understanding of foil journal bearings have enabled several new commercial products in recent years. These products include oil-free turbochargers for both heavy trucks and automobiles, high speed electric motors, microturbines for distributed power generation, and turbojet engines. However, the foil thrust bearing has not received a complimentary level of research and therefore has become the weak link of oil-free turbomachinery. In an effort to both provide machine designers with basic performance parameters and to elucidate the underlying physics of foil thrust bearings, NASA Glenn Research Center has completed an effort to experimentally measure the performance of simple gas foil thrust bearing in air. The database includes simple bump foil supported thrust bearings with full geometry and manufacturing techniques available to the user. Test conditions consist of air at ambient pressure and temperatures up to 500 C and rotational speeds to 55,000 rpm. A complete set of axial load, frictional torque, and rotational speed is presented for two different compliant sub-structures and inter-pad gaps. Data obtained from commercially available foil thrust bearings both with and without active cooling is presented for comparison. A significant observation made possible by this data set is the speed-load capacity characteristic of foil thrust bearings. Whereas for the foil journal bearing the load capacity increases linearly with rotational speed, the foil thrust bearing operates in the hydrodynamic high speed limit. In this case, the load capacity is constant and in fact often decreases with speed if other factors such as thermal conditions and runner distortions are permitted to dominate the bearing performance.

Bruckner, Robert J.↗

NASA NTRS1988

Technology developments for a compound cycle engine

The Compound Cycle Engine (CCE) is a highly turbocharged, power compounded power plant which combines the light weight pressure rise capability of a gas turbine with the high efficiency of a diesel. When optimized for a rotorcraft, the CCE will reduce fuel burned for a typical 2 hour (plus 30 min reserve) mission by 30 to 40 percent when compared to a conventional advanced technology gas turbine. The CCE can provide a 50 percent increase in range-payload product on this mission. Results of recent activities in a program to establish the technology base for a CCE are presented. The objective of this program is to research and develop those critical technologies which are necessary for the demonstration of a multicylinder diesel core in the early 1990s. A major accomplishment was the initial screening and identification of a lubricant which has potential for meeting the material wear rate limits of the application. An in-situ wear measurement system also was developed to provide accurate, readily obtainable, real time measurements of ring and liner wear. Wear data, from early single cylinder engine tests, are presented to show correlation of the in-situ measurements and the system's utility in determining parametric wear trends. A plan to demonstrate a compound cycle engine by the mid 1990s is included.

Bobula, George A.↗

NASA NTRS1992

Screen Cage Ion Plating (SCIP) and scratch testing of polycrystalline aluminum oxide

A screen cage ion plating (SCIP) technique was developed to apply silver films on electrically nonconducting aluminum oxide. It is shown that SCIP has remarkable throwing power; surfaces to be coated need not be in direct line of sight with the evaporation source. Scratch tests, employing a diamond stylus with a 200 micro m radius tip, were performed on uncoated and on silver coated alumina. Subsequent surface analysis show that a significant amount of silver remains on the scratched surfaces, even in areas where high stylus load produced severe crack patterns in the ceramic. Friction coefficients were lowered during the scratch tests on the coated alumina indicating that this modification of the ion planting process should be useful for applying lubricating films of soft metals to electrical insulating materials. The very good throwing power of SCIP also strongly suggests general applicability of this process in other areas of technology, e.g., electronics, in addition to tribology.

Spalvins, Talivaldis↗

NASA NTRS1997

Neural Network Control of a Magnetically Suspended Rotor System

Abstract Magnetic bearings offer significant advantages because of their noncontact operation, which can reduce maintenance. Higher speeds, no friction, no lubrication, weight reduction, precise position control, and active damping make them far superior to conventional contact bearings. However, there are technical barriers that limit the application of this technology in industry. One of them is the need for a nonlinear controller that can overcome the system nonlinearity and uncertainty inherent in magnetic bearings. This paper discusses the use of a neural network as a nonlinear controller that circumvents system nonlinearity. A neural network controller was well trained and successfully demonstrated on a small magnetic bearing rig. This work demonstrated the feasibility of using a neural network to control nonlinear magnetic bearings and systems with unknown dynamics.

Choi, Benjamin↗

NASA NTRS1998

Neural Network Control of a Magnetically Suspended Rotor System

Magnetic bearings offer significant advantages because they do not come into contact with other parts during operation, which can reduce maintenance. Higher speeds, no friction, no lubrication, weight reduction, precise position control, and active damping make them far superior to conventional contact bearings. However, there are technical barriers that limit the application of this technology in industry. One of them is the need for a nonlinear controller that can overcome the system nonlinearity and uncertainty inherent in magnetic bearings. At the NASA Lewis Research Center, a neural network was selected as a nonlinear controller because it generates a neural model without any detailed information regarding the internal working of the magnetic bearing system. It can be used even for systems that are too complex for an accurate system model to be derived. A feed-forward architecture with a back-propagation learning algorithm was selected because of its proven performance, accuracy, and relatively easy implementation.

Choi, Benjamin B.↗

NASA NTRS1968

Squeeze-film gas bearing technology

Squeeze-film bearing is studied to develop a low-friction suspension for the output-axis gimbal of a single-degree-of-freedom gyroscope. Included are a review of pertinent literature, the theory of squeeze-film lubrication, and design elements.

Pan, C. H. T.↗

NASA NTRS1984

Advanced propfan drive system characteristics and technology needs

Characteristics of a single-rotation drive system for an advanced turboprop engine are described. The gearbox is designed for a 10,000 shp three-spool, free-turbine engine and is installed in a wing-mounted nacelle. An offset gearbox from an earlier APET study provided the background for the preliminary design and benefit analysis for a 1990s advanced technology versus 1980s state-of-the-art gearbox. High efficiencies were achieved for both designs with inherently high life goals. Increases in design allowables for gears, bearings, and lubricants resulted in improvements for the 1990s design.

Anderson, R. D.↗

NASA NTRS1997

Fastener Design Course

Richard T. Barrett, Senior Aerospace Engineer of NASA Lewis Research Center presents a comprehensive course on fastener design. A recognized expert in the field of fastener technology Mr. Barrett combines lecture, charts, illustrations with real-world experiences. Topics covered include: materials, plantings and coatings, locking methods threads, joint stiffness, rivets, inserts, nut plates, thread lubricants, design criteria, etc. A workbook accompanies the DVD.

Barrett, Richard T.↗

NASA NTRS1997

Fastener Design Course [Workbook]

Barrett, Richart T.↗

NASA NTRS2008

Preliminary Analysis for an Optimized Oil-Free Rotorcraft Engine Concept

Recent developments in gas foil bearing technology have led to numerous advanced high-speed rotating system concepts, many of which have become either commercial products or experimental test articles. Examples include Oil-Free microturbines, motors, generators and turbochargers. The driving forces for integrating gas foil bearings into these high-speed systems are the benefits promised by removing the oil lubrication system. Elimination of the oil system leads to reduced emissions, increased reliability, and decreased maintenance costs. Another benefit is reduced power plant weight. For rotorcraft applications, this would be a major advantage, as every pound removed from the propulsion system results in a payload benefit. Implementing foil gas bearings throughout a rotorcraft gas turbine engine is an important long-term goal that requires overcoming numerous technological hurdles. Adequate thrust bearing load capacity and potentially large gearbox applied radial loads are among them. However, by replacing the turbine end, or hot section, rolling element bearing with a gas foil bearing many of the above benefits can be realized. To this end, engine manufacturers are beginning to explore the possibilities of hot section gas foil bearings in propulsion engines. This paper presents a logical follow-on activity by analyzing a conceptual rotorcraft engine to determine the feasibility of a foil bearing supported core. Using a combination of rotordynamic analyses and a load capacity model, it is shown to be reasonable to consider a gas foil bearing core section.

Howard, Samuel A.↗

NASA NTRS2007

Conceptual Design and Feasibility of Foil Bearings for Rotorcraft Engines: Hot Core Bearings

Recent developments in gas foil bearing technology have led to numerous advanced high-speed rotating system concepts, many of which have become either commercial products or experimental test articles. Examples include oil-free microturbines, motors, generators and turbochargers. The driving forces for integrating gas foil bearings into these high-speed systems are the benefits promised by removing the oil lubrication system. Elimination of the oil system leads to reduced emissions, increased reliability, and decreased maintenance costs. Another benefit is reduced power plant weight. For rotorcraft applications, this would be a major advantage, as every pound removed from the propulsion system results in a payload benefit.. Implementing foil gas bearings throughout a rotorcraft gas turbine engine is an important long-term goal that requires overcoming numerous technological hurdles. Adequate thrust bearing load capacity and potentially large gearbox applied radial loads are among them. However, by replacing the turbine end, or hot section, rolling element bearing with a gas foil bearing many of the above benefits can be realized. To this end, engine manufacturers are beginning to explore the possibilities of hot section gas foil bearings in propulsion engines. This overview presents a logical follow-on activity by analyzing a conceptual rotorcraft engine to determine the feasibility of a foil bearing supported core. Using a combination of rotordynamic analyses and a load capacity model, it is shown to be reasonable to consider a gas foil bearing core section. In addition, system level foil bearing testing capabilities at NASA Glenn Research Center are presented along with analysis work being conducted under NRA Cooperative Agreements.

Howard, Samuel A.↗

NASA NTRS1997

Non-Coalescence Effects in Microgravity

Non-coalescence of two bodies of the same liquid and the suppression of contact between liquid drops and solid surfaces is being studied through a pair of parallel investigations being conducted at the Georgia Institute of Technology and the Microgravity Research and Support (MARS) Center in Naples, Italy. Both non-coalescence and contact suppression are achieved by exploiting the mechanism of thermocapillary convection to drive a lubricating film of surrounding gas (air) into the space between the two liquid free surfaces (non-coalescence) or between the drop free surface and the solid (contact suppression). Experiments performed to date include flow visualization experiments in both axisymmetric and (nearly) two-dimensional geometries and quantitative measurements of film thickness in the contact-suppression case in both geometries.

Neitzel, G. Paul↗

NASA NTRS1998

Non-Coalescence Effects in Microgravity

Non-coalescence of two bodies of the same liquid and the suppression of contact between liquid drops and solid surfaces is being studied through a pair of parallel investigations being conducted at the Georgia Institute of Technology and the Microgravity Research and Support (MARS) Center in Naples, Italy. Both non-coalescence and contact suppression are achieved by exploiting the mechanism of thermocapillary convection to drive a lubricating film of surrounding gas (air) into the space between the two liquid free surfaces (non-coalescence) or between the drop free surface and the solid (contact suppression). Earlier experiments performed included flow-visualization experiments in both axisymmetric and (nearly) two-dimensional geometries and quantitative measurements of film thickness in the contact-suppression case in both geometries. Work done in the second year has focused on obtaining quantitative results relating to the effects of variable air pressure, development of analytical and numerical models of non-coalescing droplets and to pursuing potential applications of these self-lubricated systems.

Neitzel, G. Paul↗

NASA NTRS1997

Non-Coalescence Effects in Microgravity

Neitzel, G. Paul↗

NASA NTRS1966

The changing technology of rolling-element bearings.

Rolling-element bearings design and material processing for special conditions, noting stress and fatigue

METAL FATIGUE↗

NASA NTRS1977

Research directed toward improved echelles for the ultraviolet

Low frequency gratings obtainable with present technology, can meet the grating-efficiency design goals for potential space telescope spectrographs. Gratings made with changes in the three specific parameters: the ruling tool profile, the coating material, and the lubricants used during the ruling process were compared. A series of coatings and test gratings were fabricated and were examined for surface smoothness with a Nomarski differential interference microscope and an electron microsocope. Photomicrographs were obtained to show the difference in smoothness of the various coatings and rulings. Efficiency measurements were made for those test rulings that showed good groove characteristics: smoothness, proper ruling depth, and absence of defects (e.g., streaks, feathered edges and rough sides). Higher grating efficiency should be correlated with the degree of smoothness of both the coating and the grating groove.

Source record↗

NASA NTRS2002

Non-Coalescence in Microgravity: Science and Technology

In this project we examine non-coalescence and non-wetting phenomena driven by either thermocapillary convection or forced motion of one surface relative to the other. In both cases, the non-coalescence or non-wetting is enabled by the existence of a lubricating layer of gas that exists to keep the two surfaces in question from coming into contact with one another. Recent progress has been made on several fronts: 1) measurement of the vibrational modes of pinned droplets; 2) development of an apparatus for the measurement of the frictional forces associated with a non-wetting droplet sliding over a solid surface; 3) measurements of the failure modes for non-wetting droplets and the influence of static electric charge on failure-, and 4) numerical simulation of a two-dimensional non-wetting droplet revealing a possible explanation for why the phenomenon has not been able to be observed using water as the droplet liquid. Issue 1) above is of relevance to the use of non-wetting droplets as positioning mechanisms and vibration dampers in a microgravity environment; issue 2) relates to the use of non-wetting droplets as nearly 'frictionless' bearings in low-load applications. Understanding of the failure modes identified in 3) is of importance to any potential application and the numerical simulations conducted under 4) allow us to obtain information about these systems that is currently not available through experimentation Each of these topics will be discussed briefly during the presentation.

Neitzel, G. Paul↗

NASA NTRS2017

Testing Aerospace Gears for Bending Fatigue, Pitting, and Scuffing

This work was motivated by the goal to increase the power to weight ratio of rotorcraft drive systems. Experiments were conducted to establish the performance of gears made from an aerospace alloy used in production aircraft. Bending fatigue, pitting, and scuffing test procedures and results are documented. The data establishes a baseline for evaluation of new technologies. Recommendations are made to improve test procedures for future work.

test method↗