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At least 199 records · Page 11

Space Shuttle Main Engine Liquid Air Insulation Redesign Lessons Learned

The Space Shuttle Main Engine Liquid Air Insulation redesign was required to prevent the reoccurance of the STS-111 High Pressure Speed Sensor In-Flight Anomaly. The STS-111 In-Flight Anomaly Failure Investigation Team's initial redesign of the High Pressure Fuel Turbopump Pump End Ball Bearing Liquid Air Insulation failed the certification test by producing Liquid Air. The certification test failure indicated not only the High Pressure Fuel Turbopump Liquid Air Insulation, but all other Space Shuttle Main Engine Liquid Air Insulation. This paper will document the original Space Shuttle Main Engine Liquid Air STS-111 In-Flight Anomaly investigation, the heritage Space Shuttle Main Engine Insulation certification testing faults, the techniques and instrumentation used to accurately test the Liquid Air Insulation systems on the Stennis Space Center SSME test stand, the analysis techniques used to identify the Liquid Air Insulation problem areas and the analytical verification of the redesign before entering certification testing, Trade study down selected to three potential design solutions, the results of the development testing which down selected the final Liquid Air Redesign are also documented within this paper.

Darrell Gaddy↗

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

Endurance life tests were run with standard-design bearings of vacuum-melted AISI 4320 and CBS-1000M at 12,500 rpm, and high-speed bearings of CBS-1000M and trough-hardened AISI M-50 at 18,500 rpm. Both sets of bearings were of 120.65 mm bore-tapered roller type, and were run under heavy combined radial and thrust loads until either fatigue failure or a preset cutoff time of 1100 hours was reached. It was found that: (1) the CBS-1000M standard-design bearings ran to a 10% life approximately six times that of the rated catalog life; (2) twelve identical bearings of AISI 4320 ran to ten times rated catalog life without failure; (3) 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; and (4) four CBS 1000M high-speed bearings ran to twenty-four times rated catalog life without spalling, cracking or fracture failures.

Parker, R. J.↗

A Passive Magnetic Bearing Flywheel

A 100 percent passive magnetic bearing flywheel rig employing no active control components was designed, constructed, and tested. The suspension clothe rotor was provided by two sets of radial permanent magnetic bearings operating in the repulsive mode. The axial support was provided by jewel bearings on both ends of the rotor. The rig was successfully operated to speeds of 5500 rpm, which is 65 percent above the first critical speed of 3336 rpm. Operation was not continued beyond this point because of the excessive noise generated by the air impeller and because of inadequate containment in case of failure. Radial and axial stiffnesses of the permanent magnetic bearings were experimentally measured and then compared to finite element results. The natural damping of the rotor was measured and a damping coefficient was calculated.

Siebert, Mark↗

Petrophysical and geomechanical properties of gas hydrate-bearing sediments recovered from Alaska North Slope 2018 Hydrate-01 Stratigraphic Test Well

Knowledge of petrophysical and geomechanical properties of gas hydrate-bearing sediments are essential for predicting reservoir response due to gas production from gas hydrate reservoirs. That information will be critical parameters for designing production well completion such as specification of depressurization pump, water storage tank, and mesh size of sand screen. In December 2018, Stratigraphic Test Well Hydrate-01 was drilled in the western part of the Prudhoe Bay Unit, Alaska North Slope as part of the technical planning effort for a future long-term production test by collaborative team of DOE/NETL, USGS, and MH21-S (Boswell et al., 2020, Collett et al., 2020, Okinaka et al., 2020). Data set of logging-while-drilling (LWD) were acquired (Haines et al., 2020, Suzuki et al., 2019) and core sampling depth was determined on-site.Side-wall pressure coring was conducted to recover gas hydrate-bearing sediments from two reservoir sections named Unit-B and Unit-D. A total of 34 cores were successfully recovered by 5 runs of a wire-line deployed pressure corer (CoreVault® System - Halliburton). Core analysis scheme of this project are shown in Figure 1. All cores were quenched in liquid nitrogen while at high pressure in the laboratory of Stratum Reservoir, LLC. at Anchorage (Figure 1, a)). And the cores were removed from the pressure corer autoclave with temperature support of dry ice and stored under liquid nitrogen at atmospheric pressure. 19 damaged cores were processed to index property measurements directly such as grain size, grain density. 4 of another 17 cores were depressurized and trimmed for making a plug to analyze petrophysical properties of host sediments. Unsteady-state permeability test was conducted to obtain relative water permeability to gas and core scale NMR T2 distribution measurement was performed for evaluating pore size distribution at Houston (Figure 1, b)). Remained high quality 13 cores were preserved with gas hydrate for advanced laboratory analysis. National Institute of Advanced Industrial Science and Technology, as a part of the Japanese National Hydrate Research Program (MH21-S, funded by Ministry of Economy, Trade and Industry), received the samples at Sapporo, Japan for advanced core analysis. High-resolution X-ray CT was used to analyze the quality of the samples, which showed undisturbed lithological layers. Cores were lathed into cylindrical shape and distributed for multi property measurements (Figure 1, c)).<p>As a result, sediment from Unit-D is categorized as silty sand at ~37% porosity with ~80% gas hydrate saturation. An average hydration number n = 6.16 was measured by Raman spectroscopy. An average intrinsic permeability of ~400 mD and in situ effective permeability (with hydrate) on the order of ~10 mD. The Unit B recovered cores consisted of well sorted sand at ~40% porosity with ~95% gas hydrate saturation. An average intrinsic permeability of ~1 Darcy and in situ effective permeability on the order of ~30 mD was measured for the Unit B cores. There was a small permeability reduction due to porosity loss with increasing effective stress that simulated consolidation behavior along with depressurization in the highly permeable sandy sediment. The apparent minimum change in porosity and permeability may be caused by the low compressibility of quartz sand grains in the recovered cores. XRD and thermal conductivity analysis also suggested high quartz content. Triaxial compression tests established internal friction angles based on the Mohr-Coulomb's failure criterion, which are 40° for hydrate-bearing sediment and 29.8° for hydrate free sediment.</p>

Yoneda, Jun↗

Fatigue-crack propagation behavior in a high-carbon chromium SUJ2 bearing steel: Role of microstructure

High-carbon chromium martensite steels are commonly selected for bearing components in the power generation, automotive and aerospace industries where fatigue failure is a major concern. Accordingly, it is of importance to elucidate the structure-property relationships governing the fatigue properties of such bearing steels. Here, the role of microstructure in influencing the fatigue-crack propagation behavior of a high-carbon chromium SUJ2 bearing steel is examined with emphasis on three martensitic structures: (i) a fine-grained (~10 μm) structure with intragranular (but no intergranular) carbides, (ii) a coarser-grained (~25 μm) structure with discontinuous grain-boundary carbides primarily near triple junctions, and (iii) a coarse-grained (~31 μm) structure with continuous grain-boundary carbides. Although growth rates were fairly similar above ~10 -8 m/cycle, significant differences in behavior were observed at lower, near-threshold growth rates; specifically at a load ratio of 0.1, the ΔKth fatigue threshold was increased from 3.8 MPa m ½ in the fine-grained structure to 5.9 to 6.3 MPa m ½ in the two coarser-grained structures. The dominant factor governing such near-threshold behavior was found to be crack-tip shielding from roughness-induced crack closure, which was most pronounced in the coarser-grained structures; additionally, shielding from crack deflection and branching was apparent in these structures as the crack propagated through the network of intersecting martensite lamellae within the coarse grains. Compared to high-strength stainless steels and low-strength carbon steels, the fine-grained SUJ2 steel displays an exceptional combination of high strength and fatigue-crack growth resistance and is considered to be a superior structural alloy for bearing applications.

36 MATERIALS SCIENCE↗

Male Runners With Lower Energy Availability Have Impaired Skeletal Integrity Compared to Nonathletes

Abstract Context Female athletes, particularly runners, with insufficient caloric intake for their energy expenditure [low energy availability (EA) or relative energy deficiency] are at risk for impaired skeletal integrity. Data are lacking in male runners. Objective To determine whether male runners at risk for energy deficit have impaired bone mineral density (BMD), microarchitecture, and estimated strength. Design Cross-sectional. Setting Clinical research center. Participants 39 men (20 runners, 19 controls), ages 16–30 years. Main Outcome Measures Areal BMD (dual-energy x-ray absorptiometry); tibia and radius volumetric BMD and microarchitecture (high-resolution peripheral quantitative computed tomography); failure load (microfinite element analysis); serum testosterone, estradiol, leptin; energy availability. Results Mean age (24.5 ± 3.8 y), lean mass, testosterone, and estradiol levels were similar; body mass index, percent fat mass, leptin, and lumbar spine BMD Z-score (−1.4 ± 0.8 vs −0.8 ± 0.8) lower (P < .05); and calcium intake and running mileage higher (P ≤ .01) in runners vs controls. Runners with EA <median had lower lumbar spine (−1.5 ± 0.7, P = .028), while runners with EA ≥median had higher hip (0.3 ± 0.7 vs −0.4 ± 0.5, P = .002), BMD Z-scores vs controls. After adjusting for calcium intake and running mileage, runners with EA <median had lower mean tibial total and trabecular volumetric BMD, trabecular bone volume fraction, cortical porosity, and apparent modulus vs controls (P < .05). Appendicular lean mass and serum estradiol (R ≥ 0.45, P ≤ .046), but not testosterone, were positively associated with tibial failure load among runners. Conclusions Despite weight-bearing activity, skeletal integrity is impaired in male runners with lower caloric intake relative to exercise energy expenditure, which may increase bone stress injury risk. Lower estradiol and lean mass are associated with lower tibial strength in runners.

Haines, Melanie S. (ORCID:0000000310024754)↗

Effect of wall thickness and material on flexural fatigue of hollow rolling elements

Hollow cylindrical bars were tested in a rolling-contact fatigue tester to determine the effects of material and outside diameter to inside diameter (OD/ID) ratios on fatigue failure mode and subsequent failure propagation. The range of applied loads with OD/ID ratios of 2.0, 1.6, 1.4, and 1.2 resulted in maximum tangential tensile stresses ranging from 165 to 655 MPa at the bore surface. Flexural failures of the hollow test bars occurred when this bore stress was 490 MPa or greater with AISI 52100 hollow bars and 338 MPa or greater with AISI M-50 hollow bars. Good correlation was obtained in relating the failures of these hollow bars with flexural failures of drilled balls from full-scale bearing test published previously.

Bamberger, E. N.↗

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↗

Relative Lifetimes of Several Space Liquid Lubricants Using a Vacuum Spiral Orbit Tribometer (SOT)

A vacuum spiral orbit rolling contact tribometer (SOT) was used to determine the relative lifetimes of several unformulated space liquid lubricants. The lubricants tested included a synthetic hydrocarbon (Pennzane 2001 A), three perfluoropolyethers (Krytox 143AC, Fomblin Z25, and Brayco 815Z), three silahydrocarbons (a tri, a tetra, and a penta) and a polyalphaolefin (Nye PAO-100). The SOT simulates the ball motions in an angular contact bearing and tribochemically degrades microgram quantities of lubricant. Test failure is determined when a preset friction coefficient is exceeded. Relative lifetime (orbits/micro-g) is defined as the number of ball orbits to failure divided by the amount of lubricant on the ball. Conditions included 10 to 200 rpm rotational speed, approximately 50 micro-g lubricant, an initial vacuum < 1.3x10(exp -6) Pa, room temperature (approximately 23 C), a mean Hertzian stress of 1.5 GPa, and 440 C stainless steel specimens. Lubricated lifetimes from longest to shortest were Pennzane 2001 A, the silahydrocarbons and the PAO-100, 143AC, ZI-5, and then 815Z. Relative lifetimes compare favorably to full-scale vacuum gimbal bearing tests. The effect of varying the mean Hertzian stress on the lifetime of some of the lubricants was examined.

Jansen, Mark J.↗

Lubrication of nonconformal contacts

Minimum film thickness results for piezoviscous-rigid regime of lubrication are developed for a compressible Newtonian fluid with Roelands viscosity. The results provide a basis for the analysis and design of a wide range of machine elements operating in the piezoviscous-rigid regime of lubrication. A new numerical method of calculating elastic deformation in contact stresses is developed using a biquadratic polynomial to approximate the pressure distribution on the whole domain analyzed. The deformation of every node is expressed as a linear combination of the nodal pressures whose coefficients can be combined into an influence coefficient matrix. This approach has the advantages of improved numerical accuracy, less computing time and smaller storage size required for influence matrix. The ideal elastohydrodynamic lubrication is extended to real bearing systems in order to gain an understanding of failure mechanisms in machine elements. The improved elastic deformation calculation is successfully incorporated into the EHL numerical scheme. Using this revised numerical technique and the flow factor model developed by Patir and Cheng (1978) the surface roughness effects on the elastohydrodynamic lubrication of point contact is considered. Conditions typical of an EHL contact in the piezoviscous-elastic regime entrained in pure rolling are investigated. Results are compared with the smooth surface solutions. Experiments are conducted to study the transient EHL effects in instrument ball bearings.

Jeng, Y. R.↗

Evaluation of axial lock-up of space shuttle main engine bearings from high pressure oxygen turbopump

The mainshaft support bearings of long life turbopumps for use on the space shuttle were evaluated to determine possible causes of failure. Specific aspects examined include the sensitivity of 15 degree versus 25 degree contact angle bearings with regard to heat damage and thermal runaway, the L/D aspects of the turbine end bearing pair with regard to hang-up due to cocking, the hang-up required to support a 44.5 KN axial load without cartridge slipping, the outer race growth as a result of a 44.5 KN axial load, and bearing torque as a function of axial load. Results indicate that hang-up of the cartridge due to bearing heating is a serious problem especially if poor lubrication of the bearing occurs and that race growth due to axial load can contribute to cartridge lock-up. The experimental evaluation of bearing performance under axial loads indicates that the bearing torque is a strong function of surface lubrication.

Kannel, J. W.↗

Evaluation of Perfluoropolyether Lubricant Lifetime in the High Stress and High Stress-Cycle Regime for Mars Applications

The successful operation of long-life, highly loaded mechanisms used for planetary exploration or autonomous structures assembly will depend upon the ability to effectively lubricate rolling-element bearings. As new tools are developed (i.e., drill, abraders, robotic manipulators, etc.) that interact with their environment in a more direct manner, lubricants will be pushed past the bounds that current scientific literature has published. This paper details results from bearing lubrication lifetime testing performed in support of Honeybee Robotics development of the Mars Science Laboratory (MSL) Surface Removal Tool (SRT). This testing was done due to the lack of available data in research literature that is applicable to the lubrication regime the SRT bearings are being designed for. Based on the test results, the chosen bearing arrangement can be used for the SRT Grind Shaft bearings with the use of a Braycote Micronic 601EF grease-plate with a 10 vol% grease slurry fill (50/50 wt% Braycote Micronic 601EF and Brayco 815Z). This arrangement showed no signs of detrimental degradation over the course of the 3x life test. The purely grease-plated bearing ran at a consistently higher torque and showed signs of failure beginning at approximately 2.2 x 10(exp 7) revs (approximately 6.3 x 10(exp 7) stress-cycles) with a torque over-limit failure at approximately 4.5 x 10(exp 7) revs (approximately 1.3 x 10(exp 8) stress-cycles). Barring cold-start torque margin limitations, it is recommended that any long-life bearing application include some vol% grease-pack in addition to a standard grease-plate to reduce parasitic torque and increase bearing life. While these results are specific to a particular environment and loading condition, they demonstrate the extended capabilities of a commonly used flight lubricant outside of the range that is published in current research literature.

Herman, Jason↗

An apparatus for bearing-bypass testing of bolted joints

A dual-control test system measuring the strength of graphite/epoxy specimens under tension and compression for a wide range of bearing-bypass load ratios is presented. The bearing-bypass strengths of single-fastener specimens are measured for damage onset and ultimate failure and are plotted against one another. The results indicate that an initiated damage grows to failure in the same mode for most cases. However, if the damage is initiated in the compression-reacted-bearing mode, the specimens fail in the offset-compression mode. It is concluded that this type of transition can occur in multi-fastener joints under compression and complicate the strength predictions.

Crews, J. H., Jr.↗

Future Issues and Approaches to Health Monitoring and Failure Prevention for Oil-Free Gas Turbines

Recent technology advances in foil air bearings, high temperature solid lubricants and computer based modeling has enabled the development of small Oil-Free gas turbines. These turbomachines are currently commercialized as small (<100 kW) microturbine generators and larger machines are being developed. Based upon these successes and the high potential payoffs offered by Oil-Free systems, NASA, industry, and other government entities are anticipating Oil-Free gas turbine propulsion systems to proliferate future markets. Since an Oil-Free engine has no oil system, traditional approaches to health monitoring and diagnostics, such as chip detection, oil analysis, and possibly vibration signature analyses (e.g., ball pass frequency) will be unavailable. As such, new approaches will need to be considered. These could include shaft orbit analyses, foil bearing temperature measurements, embedded wear sensors and start-up/coast down speed analysis. In addition, novel, as yet undeveloped techniques may emerge based upon concurrent developments in MEMS technology. This paper introduces Oil-Free technology, reviews the current state of the art and potential for future turbomachinery applications and discusses possible approaches to health monitoring, diagnostics and failure prevention.

DellaCorte, Christopher↗

Radial Loading of Hydrodynamic Bearings Due to Magnetic Variation

Anomalies during integration of a small-scale hydrodynamic pump motor prompted an investigation into all sources of radial loading on the bearings, and revealed that overall loads were insufficiently characterized. Experimental measurements demonstrated that magnetic forces in the pump motor contributed to significant amounts of radial loading on the bearings, potentially causing wear over long periods of operation and premature failures. The magnitude of these magnetic forces was determined for the rotor and stator separately, as well as for the rotor-stator assembly by designing various experimental setups able to recreate the pump motor without hydrodynamic bearings. Characterization of these magnetic forces led to changes in manufacturing processes and enabled selective choices of components, improving the pump motor hardware in order to meet NASA’s Europa Clipper project requirements.

Underhill, Micheal↗

Effect of Fiber Orientation on Ball Failures Under Rolling-contact Conditions

The rolling-contact fatigue spin rig was used to test bails of a bearing steel at maximum Hertz stresses of 600,000 to 750,000 psi. The effect of fiber orientation was observed with the ball track restricted to passing directly over the poles, coincident with the equator, or randomly around the ball. The polar areas were found to be weaker in fatigue than the nonpolar areas. This resulted in a much greater portion of the failures occurring in the polar areas than would be expected from a homogeneous material. The early failures are discussed.

MATERIALS, PROPERTIES - FATIGUE↗

Modeling and experimental validation of a W f /W-fabrication by chemical vapor deposition and infiltration

Tungsten (W) has a unique combination of excellent thermal properties, low sputter yield, low hydrogen retention, and acceptable activation. Therefore, W is presently the main candidate for the first wall material in future fusion devices. However, its intrinsic brittleness and its further embrittlement during operation bears the risk of a sudden and catastrophic component failure. As a countermeasure, tungsten fiber-reinforced tungsten (W f /W) with extrinsic toughening is being developed. A possible synthesis route is chemical vapor deposition (CVD) using heated W fabrics as substrate. The challenge is that the growing CVD-W can isolate domains from precursor access leading to strength-reducing pores. To deepen the process understanding and to optimize the CVD parameters, models were developed with COMSOL Multiphysics and validated experimentally. W deposition rate equations as function of the temperature and the partial pressures of the precursors H 2 and WF 6 were experimentally validated in previous work. In the present article, these equations are applied to obtain partial pressures within the CVD reactor. The results are taken as input for transient simulations in the microscale, in which W coatings, growing onto multiple adjacent W fibers, were simulated via mesh deformation and remeshing. The surface-to-surface contact of the W coatings and the corresponding potential pore formation were simulated by implementing sophisticated deposition rate stop conditions. Within the measuring uncertainties of ≃ ±1%, the models are validated successfully by experimental comparison regarding the deposition rate, pore structure, and relative densities ranging from 0.6 to 0.9.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Improving the W Coating Uniformity by a COMSOL Model-Based CVD Parameter Study for Denser W f /W Composites

Tungsten (W) has the unique combination of excellent thermal properties, low sputter yield, low hydrogen retention, and acceptable activation. Therefore, W is presently the main candidate for the first wall and armor material for future fusion devices. However, its intrinsic brittleness and its embrittlement during operation bears the risk of a sudden and catastrophic component failure. As a countermeasure, tungsten fiber-reinforced tungsten (W f /W) composites exhibiting extrinsic toughening are being developed. A possible W f /W production route is chemical vapor deposition (CVD) by reducing WF 6 with H 2 on heated W fabrics. The challenge here is that the growing CVD-W can seal gaseous domains leading to strength reducing pores. In previous work, CVD models for W f /W synthesis were developed with COMSOL Multiphysics and validated experimentally. In the present article, these models were applied to conduct a parameter study to optimize the coating uniformity, the relative density, the WF 6 demand, and the process time. A low temperature and a low total pressure increase the process time, but in return lead to very uniform W layers at the micro and macro scales and thus to an optimized relative density of the W f /W composite. High H 2 and low WF 6 gas flow rates lead to a slightly shorter process time and an improved coating uniformity as long as WF 6 is not depleted, which can be avoided by applying the presented reactor model.

36 MATERIALS SCIENCE↗