SEARCH · Engineering Papers

Results for “lubricant technologies”

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.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 253 records · Page 14

All sources NASA NTRS DOE OSTI

DOE OSTI2025

Bridging microscopic dynamics and rheology in the yielding of charged colloidal suspensions

The yielding of soft materials is critical to many natural and industrial processes, yet experimental insights into microscopic aspects of yielding are limited. This study combines angle X-ray scattering, X-ray photon correlation spectroscopy, and in situ rheology (Rheo-SAXS-XPCS) with fast lubrication dynamics simulations to examine how interparticle interactions influence yielding in charged colloidal suspensions. By tuning attraction through salt addition, we compare repulsive and attractive systems under deformation. Repulsive suspensions yield uniformly with Andrade-like creep and minimal structural change. In contrast, attractive suspensions show complex behaviors, including shear banding, delayed yielding, and resolidification, governed by transient dynamics at shear band interfaces. These results directly link microscopic particle dynamics to macroscopic flow and demonstrate how interaction potentials control rheological behavior. This work offers a framework for designing soft materials with tailored properties for applications in coatings, food processing, drug delivery, and other technologies requiring precise mechanical control.

Molecular Dynamics Simulation↗

NASA NTRS2018

Space: An Exciting Place to Work! Working in Space (without Ever Leaving Earth?)

In addition to the highly visible astronauts, NASA personnel include thousands of engineers, scientists, technicians and support staff. These vital employees develop technologies and solution to the many problems the Agency faces while undertaking space exploration. In this presentation to STEM students, the engineering that has been done to develop and maintain critical mechanism on the International Space Station will be reviewed and discussed. The overall goal of the presentation is to clearly show that many individuals can make meaningful contributions to space exploration without ever leaving the earth.

bearings↗

NASA NTRS1984

Ground test challenges in the development of the Space Shuttle orbiter auxiliary power unit

A conventional aircraft hydraulic system design approach was selected to provide fluid power for the Space Shuttle Orbiter. Developing the power unit, known as the Auxiliary Power Unit (APU), to drive the hydraulic pumps presented a major technological challenge. A small, high speed turbine drive unit powered by catalytically decomposed hydrazine and operating in the pulse mode was selected to meet the requirement. Because of limitations of vendor test facilities, significant portions of the development, flight qualification, and postflight anomaly testing of the Orbiter APU were accomplished at the Johnson Space Center (JSC) test facilities. This paper discusses the unique requirements of attitude, gravity forces, pressure profiles, and thermal environments which had to be satisfied by the APU, and presents the unique test facility and simulation techniques employed to meet the ground test requirements. In particular, the development of the zero-g lubrication system, the development of necessary APU thermal control techniques, the accomplishment of integrated systems tests, and the postflight investigation of the APU lube oil cooler behavior are discussed.

Chaffee, N. H.↗

DOE OSTI2020

Development of Ionic Liquid-Additized, GF-5/6 Compatible Low-Viscosity Oils for Automotive Engine and Rear Axle Lubrication for 4% Improved Fuel Economy

This joint project among ORNL, GM, and DRO successfully developed ionic liquid-additized low viscosity lubricants, SAE 0W-12 and 70W-80, for both IC engine and rear axle lubrication, respectively, and demonstrated combined vehicle fuel economy improvement (FEI). Phosphonium-alkylphosphate ILs have been found to be the most effective among the candidates in protecting surface damage from both sliding wear and rolling contact fatigue, and optimal IL concentrations have been determined. The IL’s impact on three-way catalyst seems to be significantly less adverse than the conventional ZDDP. Oil formulations were optimized for both energy efficiency and wear protection. Tribological bench testing of the IL-additized low-viscosity oils showed at least 40% lower boundary friction, more than 60% lower elastohydrodynamic friction, and greater than 50% less wear compared with commercial baselines. IL-additized lubricants have demonstrated FEI by 9.9% in engine dynamometer tests under extreme conditions and 6.9% increased power output in gear rig tests. Prototype IL-additized engine oil and rear axle fluid exhibited combined FEI of 1.39% and 3.24% benchmarked against the state-of-the-art baselines in vehicle testing of fresh oils under the Federal Test Procedure (FTP) city cycle and Highway Fuel Economy Driving Schedule (HWFET), respectively. Used oil analysis suggested that the IL-additized low-viscosity oils produced less wear than the commercial baselines. The gained fundamental understanding and demonstrated FEI in this work pave the way for future development and implementation of the ionic liquid technology.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS2012

Design and Manufacturing Considerations for Shockproof and Corrosion-Immune Superelastic Nickel-Titanium Bearings for a Space Station Application

An intermetallic nickel-titanium alloy, 60NiTi (60wt%Ni, 40wt%Ti), is a promising tribological material for space mechanisms. 60NiTi offers a broad combination of physical properties that make it unique among bearing materials. 60NiTi is hard, electrically conductive, highly corrosion resistant, readily machined prior to final heat treatment, easily lubricated and is non-magnetic. It also falls within the class of superelastic alloys and can elastically endure large strains (beyond 5 percent) making it highly resistant to excessive and unexpected (shock) loads. Key material properties and characteristics such as elastic modulus, tensile fracture sensitivity and residual stress behavior, however, differ from conventional alloys such as steel and this significantly affects bearing design and manufacturing. In this paper, the preliminary design and manufacture of ball bearings made from 60NiTi are considered for a highly corrosive, lightly loaded, low speed bearing application found inside the International Space Station s water recycling system. The information presented is expected to help guide more widespread commercialization of this new technology into space mechanism and other applications.

DellaCorte, Christopher↗

DOE OSTI2022

Investigations in the tape-to-tape contact resistance and contact composition in superconducting CORC ® wires

Conductor on Round Core (CORC®) wires and cables, constructed from multiple layers of helically wound REBa 2 Cu 3 O 7–δ tapes, are a promising cable technology for high field magnet applications. An important feature of high-temperature superconductor cables is the ability to share current between conductors, allowing current to bypass drops in I c and minimizing the risk of hot spot formation, which could lead to potential burnout in the superconductor. In contrast to stacked-tape cables, which have continuous contact between tapes, in CORC® the transfer points occur at discrete tape crossovers. The tape-to-tape contact resistance, R c , plays a critical role in the current sharing capabilities and current distribution in cables. For the work reported here, special CORC® wires were manufactured using different winding parameters to investigate variations in R c . Variations comprised inclusion of a lubricant, different lubricant conductivity, inclusion of pre-tinning, and heating briefly to melt the solder. Cables were first tested as straight lengths, followed by bending to a 10 cm diameter. In straight cables R c values ranged from 1 to over 1000 μΩ cm 2 , depending on cabling parameters, with the highest values being found for cables made by the present 'standard' process. Bending the cables to a 10 cm diameter decreased R c by a factor 2–5. Tinning with PbSn decreased R c by three orders of magnitude compared to standard CORC® wires, and heat treating wires with tinned conductor resulted in only a small further decrease in R c . Based on the measured R c at an electric field of 1 μV cm –1 the resulting current transfer length between layers can range from a few millimeters to a tens of centimeters. Examination of contacts with a laser confocal microscope showed plastic deformation of the copper at the edges of the contact overlap area, apparently caused by thicker plating at tape edges digging into the copper of neighboring layers. These images reveal that only a fraction of the total contact surface may actually be touching when there is nothing to compensate for height differential. Images of the PbSn coated tapes indicated that application of solder produces a much more uniform contact surface and higher contact area. Furthermore, imaging of CORC® cross-sections confirmed that in the non-tinned cables there are many regions where tapes are not in contact, while in contrast the PbSn cable shows significantly more contact between the tapes. These different imaging techniques reveal that tape surface morphology is a significant parameter in determining R c .

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2021

Rheological and pumping behaviour of 3D printable cementitious materials with varying aggregate content

3D printing with cementitious materials is an emerging technology and provides an active area of research. Despite this, there are only limited studies that examine the pumping behaviour of high yield stress fluids such as printable concrete. We present a study on the rheological behaviour of 3D printable cementitious materials with different aggregate-to-binder ratios (a/b) and analyse the pumping and printing characteristics with the measured rheological parameters. We observed that an increase in a/b resulted in a significant increase of plastic viscosity, and a nominal increase in yield stress and storage modulus. The variation in plastic viscosity and yield stress with increasing aggregate content was analysed with the Krieger-Dougherty and Chateau-Ovarlez-Trung model, respectively. Also, the rheological properties of the paste rich lubrication layer during pumping were determined with the help of a tribometer. The yield stress and viscous constant of the lubrication layer increase with the increase in a/b. The pumping pressure predictions were carried out by a suitable theoretical model by considering appropriate flow conditions for different mixtures. The variation in critical height of printed elements with an increase in a/b was correlated with the observed rheological parameters.

36 MATERIALS SCIENCE↗

NASA NTRS1985

Advanced Gas Turbine (AGT) technology report

Engine testing, ceramic component fabrication and evaluation, component performance rig testing, and producibility experiments at Pontiac comprised AGT 100 activities of this period, January to December 1984. Two experimental engines were available and allowed the evaluation of eight experimental assemblies. Operating time accumulated was 115 hr of burning and 156 hr total. Total cumulative engine operating time is now 225 hr. Build number 11 and 12 of engine S/N 1 totaled 28 burning hours and constituted a single assembly of the engine core--the compressor, both turbines, and the gearbox. Build number 11 of engine S/N 1 included a 1:07 hr continuous test at 100% gasifier speed (86,000 rpm). Build number 8 of engine S/N 2 was the first engine test with a ceramic turbine rotor. A mechanical loss test of an engine assembly revealed the actual losses to be near the original design allowance. Component development activity included rig testing of the compressor, combustor, and regenerator. Compressor testing was initiated on a rig modified to control the transfer of heat between flow path, lubricating oil, and structure. Results show successful thermal decoupling of the rig and lubricating/cooling oil. Rig evaluation of a reduced-friction compressor was initiated. Combustor testing covered qualification of ceramic parts for engine use, mapping of operating range limits, and evaluation of a relocated igniter plug. Several seal refinements were tested on the hot regenerator rig. An alternate regenerator disk, extruded MAS, was examined and found to be currently inadequate for the AGT 100 application. Also, a new technique for measuring leakage was explored on the regenerator rig. Ceramic component activity has focused on the development of state-of-the-art material strength characteristics in full-scale hardware. Injection-molded sintered alpha-SiC rotors were produced at Carborundum in an extensive process and tool optimization study.

Source record↗

DOE OSTI2026

Hydrogenolysis Versus Hydrocracking for Polyolefin Upcycling

Global plastic production has reached 413.8 million metric tons in 2024 and is forecasted to surpass 1.2 billion metric tons by 2050. Polyolefins, mainly polyethylene (PE) and polypropylene (PP), dominate single-use packaging and account for approximately 55% of global plastic waste. The chemical inertness that makes these materials desirable for commercial applications also renders them persistent in the environment. Current recycling technologies have proven to be insufficient to divert plastic waste from landfills or environmental loss due to technical limitations and poor economic incentives. Conventional mechanical recycling is a form of downcycling, in which the polymer remelting process results in products with inferior material properties and reduced market value. Pyrolysis, a thermochemical route used for the chemical recycling of plastic wastes into refinery feedstock, requires severe conditions, typically 400–600 °C in an oxygen-free environment. The high temperature drives up energy costs and produces a wide range of poorly defined products, including undesirable light gases and heavy tars that pose challenges for downstream processing. As an alternative, catalytic chemical recycling offers a promising route for converting waste polyolefins back into value-added hydrocarbons—such as fuels, lubricant base oils, and other chemical feedstocks—at temperatures typically below 300 °C. This opinion article focuses on two dominant pathways in heterogeneous catalysis that are used to cleave the C–C bonds of polyolefins: hydrogenolysis and hydrocracking. Both catalytic pathways have the potential to selectively convert polyolefin waste into valuable fuels and chemical feedstocks under mild conditions. Notably, while hydrocracking primarily yields branched hydrocarbon products, hydrogenolysis predominantly produces linear hydrocarbons. Here, we compare the mechanisms and catalyst designs for hydrocracking and hydrogenolysis, analyze critical technical challenges from catalyst stability to process engineering, and provide an outlook on how these complementary pathways can be used to repurpose plastic waste into valuable products.

Zhang, Ruoxi [Iowa State Univ., Ames, IA (United S↗

NASA NTRS2018

Two-Speed Rotorcraft Research Transmission Power-Loss Associated with the Lubrication and Hydraulic Rotating Feed-Through Design Feature

An investigation was completed into the power loss associated with a rotating feed-through (RFT) design feature used to transfer lubrication and a hydraulic control signal from the static reference frame to a rotating reference frame in the NASA GRC two-speed transmission tests conducted in the Variable-Speed Drive Test Rig. The RFT feature, not commercially available, was created specifically for this research project and is integral to all two-speed transmission configurations tested, as well as a variant concept design for a geared variable-speed transmission presented at AHS Forum 71 in 2015. The experimental set-up and results from measurements in the isolated rotating-feed-through (RFT) experiments are presented. Results were used in an overall power loss assessment for a scaled conceptual 1,000 horsepower inline concentric two-speed transmission to support a NASA Revolutionary Vertical Lift Technologies (RVLT) Technical Challenge, demonstrating 50% speed change with less than 2% power loss while maintaining current power-to-weight ratios.

Rotorcraft↗

NASA NTRS2018

Two-Speed Rotorcraft Research Transmission Power-Loss Associated with the Lubrication and Hydraulic Rotating Feed-Through Design Feature

Rotorcraft↗

NASA NTRS2018

Two-Speed Rotorcraft Research Transmission Power-Loss Associated with the Lubrication and Hydraulic Rotating Feed-Through Design Feature

Rotorcraft↗

DOE OSTI2024

Next Gen High Efficiency Boosted Engine Development

This work represents an advanced engineering research project partially funded by the U.S. Department of Energy (DOE). Ford Motor Company, FEV North America, and Oak Ridge National Laboratory collaborated to develop a next generation boosted spark ignited engine concept. The project goals, specified by the DOE, were 23% improved fuel economy and 15% reduced weight relative to a 2015 or newer light-duty vehicle. The fuel economy goal was achieved by designing an engine incorporating high geometric compression ratio, high dilution tolerance, low pumping work, and low friction. The increased tendency for knock with high compression ratio was addressed using early intake valve closing (EIVC), cooled exhaust gas recirculation (EGR), an active pre-chamber ignition system, and careful management of the fresh charge temperature. Engine weight reduction measures were implemented throughout the engine system making use of composite materials, advanced manufacturing techniques, and architectural choices. This report outlines the analytical, design, fabrication, and test work conducted for the duration of the project. The combustion system stability, EGR tolerance, and knock resistance were validated on a single cylinder engine. An inline six-cylinder engine was then designed targeting application in the Ford F150. Multi-cylinder engines were produced and tested achieving the target vehicle fuel economy improvement of 23% assessed using measured engine fuel consumption combined with a vehicle drive cycle simulation. Actions were identified and designs were demonstrated to achieve the 15% weight reduction target. This project included items covering a range of technology readiness levels. Some of the technologies explored are production ready, while others were investigated to understand the limitations for what can be achieved in a stoichiometric, gasoline-fueled, spark-ignited internal combustion engine.

42 ENGINEERING↗

NASA NTRS2014

Intentional Collaboration & Innovation Spaces at NASA

Collaboration and Innovation (C&I) are extremely popular terms in corporate jargon, and institutions with reputations for creativity often have clever and fun spaces set aside for hatching ideas and developing products or services. In and of themselves, a room full of "collaboration furniture" and electronics can't make C&I happen, any more than oil makes a gas or diesel engine run. As with the engine, though, quality lubrication is a huge factor in the smooth operation, power, and longevity of C&I activity. This paper describes spaces deliberately set up at numerous NASA field centers to support collaborative and creative thinking and processes. (Sometimes support is not so much a matter of doing things to spark discussion as it is removing constraints imposed by traditional settings and making information sharing as easy as possible.) Some spaces are rooms or suites dedicated to C&I, with significant electronic support and/or intentional lack thereof (to emphasize the human element). Others are small, comfortable "roosting places" that invite conversations of opportunity. Descriptions include the sponsoring organization, underlying goals and philosophies, lessons learned, and opportunities to excel. There is discussion about how such areas might interconnect within centers, across NASA, and with external entities using current technology and what tools and approaches may be in our future.

Scott, David W.↗

NASA NTRS1984

Status of Understanding for Bearing Materials

The structural materials and potential failure modes for high technology aircraft gas turbine bearings are reviewed. Among the failure modes discussed for iron-base through-hardened bearing materials are fatigue, surface distress, and corrosion. It is shown that the sub-surface initiated rolling-contact fatigue failure mode is reasonably well understood and in most cases can be controlled by proper material selection and design. Current bearing materials provide long life and high reliability in existing applications. A new generation of materials are being developed which will provide improved fracture toughness, better corrosion resistance, and a further extension of bearing fatigue life. Bearing problems due to surface distress, caused by a variety of surface and near surface anomalies, are less well understood. This area will require the implementation of an interdisciplinary effort to improve the level of understanding of metallic surface-lubricant reactions and interactions.

E N Bamberger↗

NASA NTRS2017

Design Solutions for the Treatment of DMSD in the ISS Water Recovery System

Dimethylsilanediol (DMSD) has been identified as a problematic organic on ISS. This contaminant was initially identified in the Water Processor Assembly (WPA) product water in 2010 by the Total Organic Carbon Analyzer (TOCA). DMSD is not a crew health hazard at the levels observed in the product water, but it may degrade the performance of the Oxygen Generation System (OGS) which uses the WPA product water for electrolysis and does impact the effective operation of the WPA catalytic reactor. To mitigate these impacts, early replacement of the Multifiltration Beds in the WPA is required. An investigation has determined that the decomposition of atmospheric polydimethylsiloxanes (PDMSs) is the primary source of DMSD in the condensate. PDMSs are prevalent on ISS from a variety of sources, including crew hygiene products, adhesives, caulks, lubricants, and various nonmetallics. These PDMSs also contribute to degradation of the CHX hydrophilic coating, rendering it hydrophobic and therefore affecting its ability to transmit water to the condensate bus. In addition, literature research has determined that PDMSs are likely oxidized to DMSD in the atmosphere when exposed to hydroxyl radicals in the ISS atmosphere. To address these mechanisms, filters have been developed for removal of PDMSs from the ISS atmosphere. However, ongoing analysis indicates a significant reduction in atmospheric PDMSs is required to achieve a measurable reduction of DMSD in the condensate. As a result, additional measures are being pursued to mitigate this issue. First, credible sources are being investigated to quantity to the extent possible the significant sources of PDMSs and identify sources that can be reasonably removed from ISS. Second, a Reverse Osmosis technology is being investigated as an alternate means for removing DMSD from the condensate. This paper summarizes the current status of the overall effort to mitigate DMSD in the US condensate.

Perry, Jay↗

DOE OSTI2020

The surface stress of biomedical silicones is a stimulant of cellular response

Silicones are commonly used for lubrication of syringes, encapsulation of medical devices, and fabrication of surgical implants. While silicones are generally viewed as relatively inert to the cellular milieu, they can mediate a variety of inflammatory responses and other deleterious effects, but the mechanisms underlying the bioactivity of silicones remain unresolved. Here, we report that silicone liquids and gels have high surface stresses that can strongly resist deformation at cellular length scales. Biomedical silicones, including syringe lubricants and fillings from FDA-approved breast implants, readily adsorb matrix proteins and activate canonical rigidity sensing pathways through their surface stresses. In 3D culture models, liquid silicone droplets support robust cellular adhesion and the formation of multinucleated monocyte-derived cell masses that recapitulate phenotypic aspects of granuloma formation in the foreign body response. Together, our findings implicate surface stress as a cellular stimulant that should be considered in application of silicones for biomedical purposes.

60 APPLIED LIFE SCIENCES↗

NASA NTRS1974

Design of H2-O2 space shuttle APU. Volume 1: APU design

The H2-O2 space shuttle auxiliary power unit (APU) program is a NASA-Lewis effort aimed at hardware demonstration of the technology required for potential use on the space shuttle. It has been shown that a hydrogen-oxygen power unit (APU) system is an attractive alternate to the space shuttle baseline hydrazine APU system for minimum weight. It has the capability for meeting many of the heat sink requirements for the space shuttle vehicle, thereby reducing the amount of expendable evaporants required for cooling in the baseline APU. Volume 1 of this report covers preliminary design and analysis of the current reference system and detail design of the test version of this reference system. Combustor test results are also included. Volume 2 contains the results of the analysis of an initial version of the reference system and the computer printouts of system performance. The APU consists of subsystems for propellant feed and conditioning, turbopower, and control. Propellant feed and conditioning contains all heat exchangers, valves, and the combustor. The turbopower subsystem contains a two-stage partial-admission pressure-modulated, 400-hp, 63,000-rpm turbine, a 0-to 4-g lubrication system, and a gearbox with output pads for two hydraulic pumps and an alternator (alternator not included on test unit). The electronic control functions include regulation of speed and system temperatures; and start-and-stop sequences, overspeed (rpm) and temperature limits, failsafe provisions, and automatic shutdown provisions.

Harris, E.↗