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At least 235 records · Page 13
All sourcesNASA NTRSDOE OSTI
NASA NTRS1985

Development of new materials for turbopump bearings

The life requirement for the angular contact ball bearings in the Space Shuttle Main Engine (SSME) high pressure oxygen turbopump (HPOTP) is 7.5 hours. In actual operation, significantly shorter service life was experienced. The objective is to identify bearing materials and/or materials processing techniques offering signficant potential for extending HPOTP bearing performance life. Interactive thermomechanical analysis of the HPOTP bearing-shaft system was performed with the SHABERTH computer program. Bearing fatigue life, ball-race contact stress, heat generation rate, bulk ring temperatures and circumferential stress in the inner rings were quantified as functions of radial load, thrust load and ball-race contact friction. Criteria established from the output of this analysis are being used for material candidate selection.

Maurer, R. E.↗
NASA NTRS1985

Computer-aided selection of materials for cryogenic turbopump bearings

The life requirement for the angular contact ball bearings in the Space Shuttle Main Engine (SSME) high-pressure-oxygen turbopump (HPOTP) is 7.5 hours. In actual operation, significantly shorter service life has been experienced. The objective of this current program is to identify bearing materials and/or materials processing techniques offering significant potential for extending HPOTP bearing performance life. A thermomechanical analysis of the HPOTP shaft/bearing system was performed with the SHABERTH (SHaft-BEaring-THermal) computer program. Bearing fatigue life, ball-race contact stress, heat generation rate, bulk ring temperatures, and circumferential stress in the inner rings were quantified as functions of radial load, thrust load, and ball-race contact friction. The analysis results were used to formulate criteria that are being used for the selection of special materials for future turbopump bearings.

Maurer, R. E.↗
NASA NTRS1999

Blood Pump Bearing System

Methods and apparatus are provided for a blood pump bearing system within a pump housing to support long-term high-speed rotation of a rotor with an impeller blade having a plurality of individual magnets disposed thereon to provide a small radial air gap between the magnets and a stator of less than 0.025 inches. The bearing system may be mounted within a flow straightener, diffuser, or other pump element to support the shaft of a pump rotor. The bearing system includes a zirconia shaft having a radiused end. The radiused end has a first radius selected to be about three times greater than the radius of the zirconia shaft. The radiused end of the zirconia shaft engages a flat sapphire endstone. Due to the relative hardness of these materials a flat is quickly produced during break-in on the zirconia radiused end of precisely the size necessary to support thrust loads whereupon wear substantially ceases. Due to the selection of the first radius, the change in shaft end-play during pump break-in is limited to a total desired end-play of less than about 0.010 inches. Radial loads are supported by an olive hole ring jewel that makes near line contact around the circumference of the shaft to support high speed rotation with little friction. The width of olive hole ring jewel is small to allow heat to conduct through to thereby prevent heat build-up in the bearing. A void defined by the bearing elements may fill with blood that then coagulates within the void. The coagulated blood is then conformed to the shape of the bearing surfaces.

Aber, Gregory S.↗
NASA NTRS2000

Blood Pump Bearing System

An apparatus is provided for a blood pump bearing system within a pump housing to support long-term highspeed rotation of a rotor with an impeller blade having a plurality of individual magnets disposed thereon to provide a small radial air gap between the magnets and a stator of less than 0.025 inches. The bearing system may be mounted within a flow straightener, diffuser, or other pump element to support the shaft of a pump rotor. The bearing system includes a zirconia shaft having a radiused end. The radiused end has a first radius selected to be about three times greater than the radius of the zirconia shaft. The radiused end of the zirconia shaft engages a flat sapphire endstone. Due to the relative hardness of these materials a flat is quickly produced during break-in on the zirconia radiused end of precisely the size necessary to support thrust loads whereupon wear substantially ceases. Due to the selection of the first radius, the change in shaft end-play during pump break-in is limited to a total desired end-play of less than about 0.010 inches. Radial loads are supported by an olive hole ring jewel that makes near line contact around the circumference of the Ir shaft to support big speed rotation with little friction. The width of olive hole ring jewel is small to allow heat to conduct through to thereby prevent heat build-up in the bearing. A void defined by the bearing elements may fill with blood that then coagulates within the void. The coagulated blood is then conformed to the shape of the bearing surfaces.

Aber, Gregory S.↗
NASA NTRS2001

Method for Providing a Jewel Bearing for Supporting a Pump Rotor Shaft

Methods for a blood pump bearing system within a pump housing to support long-term high-speed rotation of a rotor with an impeller blade having a plurality of individual magnets disposed thereon to provide a small radial air gap between the magnets and a stator of less than 0.025 inches. The bearing system may be mounted within a flow straightener, diffuser, or other pump element to support the shaft of a pump rotor. The bearing system includes a zirconia shaft having a radiused end. The radiused end has a first radius selected to be about three times greater than the radius of the zirconia shaft. The radiused end of the zirconia shaft engages a flat sapphire endstone. Due to the relative hardness of these materials a flat is quickly produced during break-in on the zirconia radiused end of precisely the size necessary to support thrust loads whereupon wear substantially ceases. Due to the selection of the first radius, the change in shaft end-play during pump break-in is limited to a total desired end-play of less than about 0.010 inches. Radial loads are supported by an olive hole ring jewel that makes near line contact around the circumference of the shaft to support high speed rotation with little friction. The width of olive hole ring jewel is small to allow heat to conduct through to thereby prevent heat build-up in the bearing. A void defined by the bearing elements may fill with blood that then coagulates within the void. The coagulated blood is then conformed to the shape of the bearing surfaces.

Gregory S Aber↗
NASA NTRS1991

"Bearingless" Bull Gear

Concept for mounting bull gear eliminates need for heavy bull-gear shaft and its supporting bearings otherwise required to react large loads. Three pairs of pinion gears supply torque to bull gear. Provides lateral support, eliminating need for bull-gear shaft and its bearing. Supporting rings with outer surfaces meeting at pitch circles react lateral loads. Intended primarily for application in helicopter in which bull gear on shaft turning rotor combines driving torques from three or more engines.

Kish, J.↗
NASA NTRS1981

Performance of jet- and inner-ring-lubricated 35 millimeter bore ball bearings operating to 2.5 million DN

Parametric tests were conducted with a 35 millimeter bore, angular contact ball bearing having a single outer land guided cage. Lubrication was achieved by flowing oil through axial grooves and radial holes machined in the inner ring of the bearing. Test conditions were a thrust load of 667 N (150 lb), shaft speeds from 48,000 to 72,000 rpm, and an oil inlet temperature of 394 K (250 F). Data from tests where the distribution of the total oil supplied to the inner ring was 50 percent for bearing lubrication and 50 percent for bearing inner ring cooling were compared with those where the distribution pattern was 25 percent lubrication and 75 percent cooling. Successful operation was experienced with both the 50-50 and 25-75 percent flow distribution patterns to 2.5 million DN. The 50-50 percent flow pattern provided the cooler bearing operation of the two inner ring lubricated bearings. The jet lubricated bearing had lower outer ring and higher inner ring temperatures than the inner ring lubricated bearings. Maximum power loss of 2.8 kW (3.7 hp) was experienced with the 25-75 percent flow distribution, and maximum percent cage slip of 7.0 occurred at 72,300 rpm with the 50-50 percent flow distribution.

Schuller, F., T.↗
DOE OSTI2024

Ring Pull Strain Analysis

Ring Pull Strain Analysis (RPSA) is a framework for analysis of Digital Image Correlation (DIC) data of gaugeless ring pull testing. It is meant for analysis of rings cut from tube cross sections and pulled in a displacement-controlled tensile test. This code takes load frame data, images take during testing, and csv files from the DIC analysis of those images and allows the user to analyze and plot data from the test. Some important features of the software include getting the strain values as a function of radial distance and angle, plotting of the strain around the ring, and stress-strain analysis of the load frame data. Additional capability is included with Ring Pull Coating Analysis (RPCA, also part of the software). Additional images are taken of samples with an outer coating and are used to correlate failure of the coating with strain values measured with DIC.

Beck, Peter↗
NASA NTRS1989

O-ring sealing verification for the space shuttle redesign solid rocket motor

As a part of the redesign of the Space Shuttle Solid Rocket Motor, the field and nozzle-to-case joints were redesigned to minimize the dynamic flexure caused by internal motor pressurization during ignition. The O-ring seals and glands for the joints were designed to accommodate both structural deflections and to promote pressure assistance. A test program was conducted to determine if a fluorocarbon elastomeric O-ring could meet this criteria in the redesigned gland. Resiliency tests were used to investigate the O-ring response to gap motion while static seal tests were used to verify design criteria of pressure assistance for sealing. All tests were conducted in face seal fixtures mounted in servo-hydraulic test machines. The resiliency of the O-ring was found to be extremely sensitive to the effects of temperature. The External Tank/Solid Rocket Booster attach strut loads had a negligible affect on the ability of the O-ring to track the simulated SRB field joint deflection. In the static pressure-assisted seal tests, as long as physical contact was maintained between the O-ring and the gland sealing surface, pressure assistance induced instantaneous sealing.

Lach, Cynthia L.↗
DOE OSTI2019

Recognition of a Key Anchor Residue by a Conserved Hydrophobic Pocket Ensures Subunit Interface Integrity in DNA Clamps

Sliding clamp proteins encircle duplex DNA and are involved in processive DNA replication and the DNA damage response. Clamp proteins are ring-shaped oligomers (dimers or trimers) and are loaded onto DNA by an ATP-dependent clamp loader complex that ruptures the interface between two adjacent subunits. Here we measured the solution dynamics of the human clamp protein, proliferating cell nuclear antigen, by monitoring the change in the fluorescence of a site-specifically labeled. To unravel the origins of clamp subunit interface stability, we carried out comprehensive comparative analysis of the interfaces of seven sliding clamps. Here, we used computational modeling (molecular dynamic simulations and MM/GBSA binding energy decomposition analyses) to identify conserved networks of hydrophobic residues critical for clamp stability and ring-opening dynamics. The hydrophobic network is shared among clamp proteins and exhibits a “key in a keyhole” pattern where a bulky aromatic residue from one clamp subunit is anchored into a hydrophobic pocket of the opposing subunit. Bioinformatics and dynamic network analyses showed that this oligomeric latch is conserved across DNA sliding clamps from all domains of life and dictates the dynamics of clamp opening and closing.

59 BASIC BIOLOGICAL SCIENCES↗
NASA NTRS1988

Structural analysis of the space shuttle solid rocket booster/external tank attach ring

An External Tank (ET) attach ring is used in the Space Shuttle System to transfer lateral loads between the ET and the Solid Rocket Booster (SRB). Following the Challenger (51-L) accident, the flight performance of the ET attach ring was reviewed, and negative margins of safety and failed bolts in the attach ring were subsequently identified. The analyses described in this report were performed in order to understand the existing ET attach ring structural response to motor case internal pressurization as well as to aid in an ET attach ring redesign effort undertaken by NASA LaRC. The finite element model as well as the results from linear and nonlinear static structural analyses are described.

Dorsey, John T.↗
DOE OSTI2015

Development of Modified Pag (Polyalkylene Glycol) High VI High Fuel Efficient Lubricant for LDV Applications

Engine oils play a critical role in friction reduction. Improvements in engine oil technology steadily improved fuel economy as the industry moved through ILSAC GF-1 to GF-5 specifications. These improvements were influenced by changes in base oil chemistry, development of new friction modifiers and their treat levels, and the total additive package consisting of various other components. However, the improvements are incremental and further fuel consumption reduction opportunities are becoming more challenging. Polyalkylene glycol (PAG) based engine oils are being explored as a step forward for significant fuel consumption reduction. Although PAG fluids are used in many industrial applications, its application as an engine oil has been explored in a limited way. The objective of this project is to deep dive in exploring the applicability of PAG technology in engine oil, understanding the benefits, and limitations, elucidating the mechanism(s) for friction benefits, if any, and finally recommending how to address any limitations. The project was designed in four steps, starting with selection of lubricant technology, followed by friction and wear evaluations in laboratory bench tests which are relatively simple and inexpensive and also served as a screener for further evaluation. Selected formulations were chosen for more complex engine component level tests i.e., motored valvetrain friction and wear, piston ring friction using a motored single cylinder, and motored engine tests. A couple of formulations were further selected based on component level tests for engine dyno tests i.e., Sequence VID (ASTM D6709) for fuel economy, Sequence IVA (ASTM D6891) for valvetrain wear, and Sequence VG (ASTM D6593) for sludge and varnish protection. These are some of the industry standard tests required for qualifying engine oils. Out of these tests, a single PAG oil was selected for chassis roll dynamometer tests for fuel economy and emission measurements using FTP (Federal Test Procedure) metro/highway cycles. Five different PAG chemistries were selected by varying the starting alcohol, the oxide monomers (ethylene oxide, propylene oxide, or butylene oxide), capped or uncapped, homopolymer or random copolymer. All formulations contained a proprietary additive package and one which contained additional antiwear and friction modifier additives. Laboratory bench tests (Pin-on-Disk, High Frequency Reciprocating Rig (HFRR), Block-on-Ring, Mini-Traction Machine (MTM) identified formulations having friction, wear, and load carrying characteristics similar to or better than baseline GF-5 SAE 5W-20 oil. Motored valvetrain and motored piston ring friction tests showed nearly 50% friction reduction for some of the PAG formulations compared to GF-5 SAE 5W-20 oil. Motored engine tests showed up to 15% friction benefit over GF-5 SAE 5W-20 oil. It was observed that friction benefits are more related to PAG base oil chemistry than their lower viscosity compared to GF-5 SAE 5W-20 oil. Analysis of wear surfaces from laboratory bench tests and bucket tappets from motored valvetrain tests confirmed the presence of PAG molecules. The adsorption of these polar molecules is believed to be reason for friction reduction. However, the wear surfaces also had thin tribo-film derived from additive components. The tribo-film consisting of phosphates, sulfides, and molybdenum disulfide (when molybdenum additive was present) were observed for both GF-5 SAE 5W-20 and PAG fluids. However, when using PAG fluids, motored valvetrain tests showed high initial wear, which is believed to be due to delay in protective tribo-film formation. After the initial wear, the wear rate of PAG fluids was comparable to GF-5 SAE 5W-20 oil. The PAG oil containing additional antiwear and friction reducing additives showed low initial wear as expected. However, when this oil was evaluated in Sequence IVA test, it showed initially low wear comparable to GF-5 oil but wear accelerated with oil aging indicating rapid deterioration of additive components. ASTM Sequence VG test showed good sludge protection capability but failed to meet varnish rating for GF-5 requirement. Chassis roll dynamometer tests with PAG oil 15-1 showed about 1% fuel economy benefit over GF-5 SAE 5W-20 oil in EPA city cycles only and when the oil was slightly aged (500 miles). No fuel economy benefits could be observed in combined EPA metro/highway cycles. Also, no fuel economy benefit could be observed with continued (500- 10000 miles) oil aging. However, the emission level was comparable to the reference oil and was within EPA limits. Analysis of the PAG oil following tests showed low iron content although additive components were significantly degraded. The results indicate that PAG fluids have significant friction reduction potential but there are challenges with wear and varnish protection capabilities. These limitations are primarily because the selected additive components were chosen to provide a fluid with no metal content that forms little or no sulphated ash. Significant development work is needed to identify additive components compatible with PAG chemistry including their solubility in PAG oil. Miscibility of PAG fluids with mineral base oil is another challenge for oil change service. There is PAG chemistry (oil soluble PAG, OSP) which is soluble in mineral oils but the formulation explored in this investigation did not show significant friction reduction in motored engine tests. Again, highlighting the need for additive development for specific PAG chemistry. The thermal oxidation behavior of these oils has not been explored in this investigation and needs attention.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS1933

Working charts for the stress analysis of elliptic rings

This report presents charts which reduce the stress analysis of circular and elliptic rings of uniform cross section subjected to balanced systems of concentrated loads from a statically indeterminate problem to a statically determinate one. To demonstrate the use of the charts in the stress analysis of elliptic rings, an illustrative problem is included.

Burke, Walter F↗
DOE OSTI2016

Thermal Hydraulics Safety Analyses of TRIGA Reactor Upon Fuel Reconfiguration

Safety analyses of the Training, Research, Isotope, General Atomics (TRIGA) reactor at Kansas State University(KSU) is performed using thermal hydraulic simulations based on changes to reactivity or the volumetric heat generation rate due to changes in the positioning of the enriched fuel elements in the reactor core. If the reactivity or neutronics parameters are known, then they can be used to simulate the thermal energy state of the material which is crucial to assess the safety of the nuclear fuel inside a nuclear reactor. Several thermal hydraulics models and codes have been developed in the past to assess reactor safety. RELAP (Reactor Excursion and Leak Analysis Program) is one such tool widely used throughout the world for safety analyses. Although RELAP is considered a reliable tool by regulators, vendors, and operators, it lacks the numerical fidelity provided by 3-D computational fluid dynamics (CFD) models. This work involves the critical task of assessing safety of a research reactor upon fuel reconfiguration based on models developed in RELAP and comparing them with a commercially available 3-D CFD program. The TRIGA Mark-II reactor, designed by General Atomics and located at Kansas State University, is a class of small pool type inherently safe research reactor licensed to operate at steady state power of up to 1.25 MW. It has a cylindrical core measuring 0.45 meters diametrically and 0.38 meters axially positioned in a tank measuring 1.98 meters diametrically and 6.25 meters axially. It has uranium zirconium hydride (UZrH) fuel rods housed in stainless steel cladding material arranged in five concentric rings (B,C,D,E and F rings, in that order, moving outwards from the center). TRIGA fuel is nominally 20% enriched, but the reactivity of the fuel can be changed by using burnable poisons (not used at KSU), or by varying the total weight percent of uranium in the UZrH fuel meat. The TRIGA reactor is designed to be an inherently safe reactor and is designed to be cooled by natural convection. Thus it is of paramount importance to avoid the film boiling regime; failing to do so will subject the fuel to severe conditions, possibly resulting in its failure due to fuel/clad interactions. A high DNBR ratio is a primary consideration in the reactor core design and thus any modification in the core should ensure that this criteria is always met. In order to fully utilize the capabilities of KSU TRIGA reactor facility, it should be operated at its full capacity, i.e. 1.25 MW, which requires increasing the fuel loading in some of the E- and F-ring elements from 8.5% U (nominal) to 12.0% U (nominal). Only four elements are to be switched to 12% loading, causing local power peaking in these elements. The degree of power peaking to be expected in these 12%-loaded fuel elements was calculated based on a detailed MCNP (Monte Carlo N-Particle code) model of the reactor core. Some preliminary results of the calculations are presented in this paper based on changes in peaking factors and power levels. To predict reactor thermal behavior, axial changes in the peaking factors obtained from MCNP models were used to calculate volumetric energy density functions for a single channel one dimensional RELAP model and a three dimensional COMSOL model of the TRIGA MARK-II reactor. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2018

Location and chemical speciation of Cu in ZSM-5 during the water-gas shift reaction

Here, Cu/ZSM-5 catalysts were found to exhibit activity for the water-gas shift (WGS) reaction at temperatures over 300 °C. Nominal Cu loadings of 1, 5, and 10% on ZSM-5 were synthesized using the wetness impregnation technique and evaluated for WGS activity; with a clear trend favoring increased Cu loading (10% > 5% > 1%). X-ray diffraction (XRD) confirmed high dispersion of small Cu at low loadings while CuO crystallized at higher loadings. In-situ XRD showed an evolving transformation of CuO → Cu metal, with the appearance of a metallic copper phase at the optimum reaction conditions, particularly at the highest copper loading. In-situ diffuse reflectance infrared Fourier transform spectroscopy (DRIFTS) revealed the ability of the surface to activate H2O and adsorb CO, by the presence of HO-Al/Si and transient CO-Cu + surface species in two distinct locations (5 membered rings (2157 cm –1 ) vs channel intersections (2138 cm –1 ) within the ZSM-5 framework, that likely formed during the CuO → Cu transition. The lowest loaded Cu-ZSM-5 (1%) showed only the 5 membered ring occupied Cu + while the higher loadings showed both, with comparable temperature dependent behavior for the channel intersection Cu + . The amounts of Cu + species in each location were observed to be dependent on temperature while the 5-membered ring showed better thermal stability. In-situ ambient-pressure X-ray photoelectron spectroscopy (AP-XPS) was used to further confirm the gradual changes to the chemical state of copper (CuO → Cu 2 O → Cu) under reaction conditions.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2019

Pulsed Operation of CEBAF for JLEIC Injection

JLab Electron Ion Collider (JLEIC) is planning to use the recently upgraded 12 GeV CEBAF 1497 MHz SRF CW recirculating linac as a full-energy injector for the electron collider ring. The JLEIC electron injection requires 3-4µs long bunch trains with a 20-400ms spacing in between, resulting in uneven beam loading for the CW CEBAF. With the high beam current in JLEIC collider rings, the low duty factor of injection also requires to a very high pulsed beam current from CEBAF, exacerbating the transient beam loading issue. In this paper, we will present CEBAFs detailed pulsed operation scheme for JLEIC injection, as well as some experimental results at CEBAF.

Guo, J.↗
NASA NTRS1998

Thermal Structures Technology Development for Reusable Launch Vehicle Cryogenic Propellant Tanks

Analytical and experimental studies conducted at the NASA Langley Research Center for investigating integrated cryogenic propellant tank systems for a Reusable Launch Vehicle are described. The cryogenic tanks are investigated as an integrated tank system. An integrated tank system includes the tank wall, cryogenic insulation, Thermal Protection System (TPS) attachment sub-structure, and TPS. Analysis codes are used to size the thicknesses of cryogenic insulation and TPS insulation for thermal loads, and to predict tank buckling strengths at various ring frame spacings. The unique test facilities developed for the testing of cryogenic tank components are described. Testing at cryogenic and high-temperatures verifies the integrity of materials, design concepts, manufacturing processes, and thermal/structural analyses. Test specimens ranging from the element level to the subcomponent level are subjected to projected vehicle operational mechanical loads and temperatures. The analytical and experimental studies described in this paper provide a portion of the basic information required for the development of light-weight reusable cryogenic propellant tanks.

Johnson, Theodore F.↗
NASA NTRS2005

Thermal Structures Technology Development for Reusable Launch Vehicle Cryogenic Propellant Tanks

Analytical and experimental studies conducted at the NASA, Langley Research Center (LaRC) for investigating integrated cryogenic propellant tank systems for a reusable launch vehicle (RLV) are described. The cryogenic tanks are investigated as an integrated tank system. An integrated tank system includes the tank wall, cryogenic insulation, thermal protection system (TPS) attachment sub-structure, and TPS. Analysis codes are used to size the thicknesses of cryogenic insulation and TPS insulation for thermal loads, and to predict tank buckling strengths at various ring frame spacings. The unique test facilities developed for the testing of cryogenic tank components are described. Testing at cryogenic and high-temperatures verifies the integrity of materials, design concepts, manufacturing processes, and thermal/structural analyses. Test specimens ranging from the element level to the subcomponent level are subjected to projected vehicle operational mechanical loads and temperatures. The analytical and experimental studies described in this paper provide a portion of the basic information required for the development of light-weight reusable cryogenic propellant tanks.

Johnson, Theodore F.↗