Results for “quality installation” — Page 16

NASA NTRS1999

New Icing Cloud Simulation System at the NASA Glenn Research Center Icing Research Tunnel

A new spray bar system was designed, fabricated, and installed in the NASA Glenn Research Center's Icing Research Tunnel (IRT). This system is key to the IRT's ability to do aircraft in-flight icing cloud simulation. The performance goals and requirements levied on the design of the new spray bar system included increased size of the uniform icing cloud in the IRT test section, faster system response time, and increased coverage of icing conditions as defined in Appendix C of the Federal Aviation Regulation (FAR), Part 25 and Part 29. Through significant changes to the mechanical and electrical designs of the previous-generation spray bar system, the performance goals and requirements were realized. Postinstallation aerodynamic and icing cloud calibrations were performed to quantify the changes and improvements made to the IRT test section flow quality and icing cloud characteristics. The new and improved capability to simulate aircraft encounters with in-flight icing clouds ensures that the 1RT will continue to provide a satisfactory icing ground-test simulation method to the aeronautics community.

Irvine, Thomas B.↗

NASA NTRS2016

Aura OMI observations of regional SO2 and NO2 pollution changes from 2005 to 2015

The Ozone Monitoring Instrument (OMI) onboard NASA's Aura satellite has been providing global observations of the ozone layer and key atmospheric pollutant gases, such as nitrogen dioxide (NO2/ and sulfur dioxide (SO2/, since October 2004. The data products from the same instrument provide consistent spatial and temporal coverage and permit the study of anthropogenic and natural emissions on local-to-global scales. In this paper, we examine changes in SO2 and NO2 over some of the world's most polluted industrialized regions during the first decade of OMI observations. In terms of regional pollution changes, we see both upward and downward trends, sometimes in opposite directions for NO2 and SO2, for different study areas. The trends are, for the most part, associated with economic and/or technological changes in energy use, as well as regional regulatory policies. Over the eastern US, both NO2 and SO2 levels decreased dramatically from 2005 to 2015, by more than 40 and 80 %, respectively, as a result of both technological improvements and stricter regulations of emissions. OMI confirmed large reductions in SO2 over eastern Europe's largest coal-fired power plants after installation of flue gas desulfurization devices. The North China Plain has the world's most severe SO2 pollution, but a decreasing trend has been observed since 2011, with about a 50% reduction in 2012- 2015, due to an economic slowdown and government efforts to restrain emissions from the power and industrial sectors. In contrast, India's SO2 and NO2 levels from coal power plants and smelters are growing at a fast pace, increasing by more than 100 and 50 %, respectively, from 2005 to 2015. Several SO2 hot spots observed over the Persian Gulf are probably related to oil and gas operations and indicate a possible underestimation of emissions from these sources in bottom-up emission inventories. Overall, OMI observations have proved valuable in documenting rapid changes in air quality over different parts of the world during last decade. The baseline established during the first 11 years of OMI is indispensable for the interpretation of air quality measurements from current and future satellite atmospheric composition missions.

Pollution trends↗

NASA NTRS1988

Model-scale sound propagation experiment

The results of a scale model propagation experiment to investigate grazing propagation above a finite impedance boundary are reported. In the experiment, a 20 x 25 ft ground plane was installed in an anechoic chamber. Propagation tests were performed over the plywood surface of the ground plane and with the ground plane covered with felt, styrofoam, and fiberboard. Tests were performed with discrete tones in the frequency range of 10 to 15 kHz. The acoustic source and microphones varied in height above the test surface from flush to 6 in. Microphones were located in a linear array up to 18 ft from the source. A preliminary experiment using the same ground plane, but only testing the plywood and felt surfaces was performed. The results of this first experiment were encouraging, but data variability and repeatability were poor, particularly, for the felt surface, making comparisons with theoretical predictions difficult. In the main experiment the sound source, microphones, microphone positioning, data acquisition, quality of the anechoic chamber, and environmental control of the anechoic chamber were improved. High-quality, repeatable acoustic data were measured in the main experiment for all four test surfaces. Comparisons with predictions are good, but limited by uncertainties of the impedance values of the test surfaces.

Willshire, William L., Jr.↗

NASA NTRS2019

Uncertainty Analysis of the CE-22 Advanced Nozzle Test Facility

This paper presents methods and results of a detailed measurement uncertainty analysis that was performed for the Advanced Nozzle Test Facility, CE-22, located at the NASA Glenn Research Center. Results for the uncertainty in thrust and flow coefficients, in addition to other variables of interest, are provided. Results are presented separately as random uncertainty (characterizing errors inherent to instrument or measurement environment, impacting repeatability), systematic uncertainty (capturing inaccuracies due to measurement process, calibration, installation effects or other sources which may introduce bias), and total combined uncertainty. The statistical methods and engineering judgments used to estimate elemental uncertainties are described. The analysis tool MANTUS (Measurement Analysis Tool for Uncertainty in Systems) was used to quantify instrumentation system uncertainty, and statistical analysis and engineering judgment were used to quantify other random and systematic uncertainty sources. The Monte Carlo method was used to propagate systematic and random elemental uncertainties to determine the uncertainties of various calculated variables of interest.

data quality↗

NASA NTRS2016

Aura OMI Observations of Regional SO2 and NO2 Pollution Changes from 2005 to 2015

The Ozone Monitoring Instrument (OMI) onboard NASA's Aura satellite has been providing global observations of the ozone layer and key atmospheric pollutant gases, such as nitrogen dioxide (NO2) and sulfur dioxide (SO2), since October 2004. The data products from the same instrument provide consistent spatial and temporal coverage and permit the study of anthropogenic and natural emissions on local-to-global scales. In this paper, we examine changes in SO2 and NO2 over some of the world's most polluted industrialized regions during the first decade of OMI observations. In terms of regional pollution changes, we see both upward and downward trends, sometimes in opposite directions for NO2 and SO2, for different study areas. The trends are, for the most part, associated with economic and/or technological changes in energy use, as well as regional regulatory policies. Over the eastern US, both NO2 and SO2 levels decreased dramatically from 2005 to 2015, by more than 40 and 80 percent, respectively, as a result of both technological improvements and stricter regulations of emissions. OMI confirmed large reductions in SO2 over eastern Europe's largest coal-fired power plants after installation of flue gas desulfurization devices. The North China Plain has the world's most severe SO2 pollution, but a decreasing trend has been observed since 2011, with about a 50 percent reduction in 2012-2015, due to an economic slowdown and government efforts to restrain emissions from the power and industrial sectors. In contrast, India's SO2 and NO2 levels from coal power plants and smelters are growing at a fast pace, increasing by more than 100 and 50 percent, respectively, from 2005 to 2015. Several SO2 hot spots observed over the Persian Gulf are probably related to oil and gas operations and indicate a possible underestimation of emissions from these sources in bottom-up emission inventories. Overall, OMI observations have proved valuable in documenting rapid changes in air quality over different parts of the world during last decade. The baseline established during the first 11 years of OMI is indispensable for the interpretation of air quality measurements from current and future satellite atmospheric composition missions.

SO2 and NO2↗

NASA NTRS2018

The Dawn of Geostationary Air Quality Monitoring: Case Studies from Seoul and Los Angeles

With the near-future launch of geostationary pollution monitoring satellite instruments over North America, East Asia, and Europe, the air quality community is preparing for an integrated global atmospheric composition observing system at unprecedented spatial and temporal resolutions. One of the ways that NASA has supported this community preparation is through demonstration of future space-borne capabilities using the Geostationary Trace gas and Aerosol Sensor Optimization (GeoTASO) airborne instrument. This paper integrates repeated high-resolution maps from GeoTASO, ground-based Pandora spectrometers, and low Earth orbit measurements from the Ozone Mapping and Profiler Suite (OMPS), for case studies over two metropolitan areas: Seoul, South Korea on June 9, 2016 and Los Angeles, California on June 27, 2017. This dataset provides a unique opportunity to illustrate how geostationary air quality monitoring platforms and ground-based remote sensing networks will close the current spatiotemporal observation gap. GeoTASO observes large differences in diurnal behavior between these urban areas, with NO2 accumulating within the Seoul Metropolitan Area through the day but NO2 peaking in the morning and decreasing throughout the afternoon in the Los Angeles Basin. In both areas, the earliest morning maps exhibit spatial patterns similar to emission source areas (e.g., urbanized valleys, roadways, major airports). These spatial patterns change later in the day due to boundary layer dynamics, horizontal transport, and chemistry. The nominal resolution of GeoTASO is finer than will be obtained from geostationary platforms, but when NO2 data over Los Angeles are up-scaled to the expected resolution of TEMPO, spatial features discussed are conserved. Pandora instruments installed in both metropolitan areas capture the diurnal patterns observed by GeoTASO, continuously and over longer time periods, and will play a critical role in validation of the next generation of satellite measurement. These case studies demonstrate that different regions can have diverse diurnal patterns and that day-to-day variability due to meteorology or anthropogenic patterns such as weekday/weekend variations in emissions is large. Low Earth orbit measurements, despite their inability to capture the diurnal patterns at fine spatial resolution, will be essential for intercalibrating the geostationary radiances and cross-validating the geostationary retrievals in an integrated global observing system.

Geostationary↗

NASA NTRS1974

Future development of IR thermovision weather satellite equipment

The self radiation of the surface being viewed is used for image synthesis in IR thermovision equipment. The installation of such equipment aboard weather satellites makes it possible to obtain cloud cover pictures of the earth's surface in a complete orbit, regardless of the illumination conditions, and also provides quantitative information on the underlying surface temperature and cloud top height. Such equipment is used successfully aboard the Soviet satellites of the Meteor system, and experimentally on the American satellites of the Nimbus series. With regard to surface resolution, the present-day IR weather satellite equipment is inferior to the television equipment. This is due primarily to the comparatively low detectivity of the IR detectors used. While IR equipment has several fundamental advantages in comparison with the conventional television equipment, the problem arises of determining the possibility for future development of weather satellite IR thermovision equipment. Criteria are examined for evaluating the quality of IR.

Listratov, A. V.↗

NASA NTRS1998

Polar Hydra Data Analysis

The science activities are: 1) Hydra is still operating successfully on orbit. 2) A large amount of analysis and discovery has occurred with the Hydra ground data processing this past year. 3) Full interdetector calibration has been implemented and documented. This intercalibration was necessitated by the incorrect installation of bias resistors in the pre-acceleration stage to the electron channeltrons. This had the effect of making the counting efficiency for electrons energy dependent as well as channeltron specific. The nature of the error had no impact on the ion detection efficiency since they have a different bias arrangement. This intercalibration is so effective, that the electron and ion moment densities are routinely produced with a level of agreement better than 20%. 4) The data processing routinely removes glint in the sensors and produces public energy time spectrograms on the web overnight. 6) Routine, but more intensive computer processing codes are operational that determine for electrons and ions, the density, the flow vector, the pressure tensor and the heat flux by numerical integration. These codes use the magnetic field to sustain the quality of their output. To gain access to this high quality magnetic field within our data stream we have monitored Russell's web page for zero levels and timing files (since his data acquisition is not telemetry synchronous) and have a local reconstruction of B for our use. We have also detected a routine anomaly in the magnetometer data stream that we have documented to Chris Russell and developed an editing algorithm to intercept these "hits" and remove them from the geophysical analysis.

Scudder, J. D.↗

NASA NTRS2010

Leading the Public Face of Space

The National Aeronautics and Space Administration (NASA) is fully committed to sharing the excitement of America's international space missions with its stakeholders, particularly the general public. In 2009, the Space Shuttle delivered astronauts to the Hubble Space Telescope to service that great observatory and to the International Space Station to install the observation platform on the Japanese Kibo laboratory. The Lunar Reconnaissance Orbiter is showing an unprecedented view of the Moon, confirming the presence of hardware left behind during the Apollo missions decades ago and helping scientists better understand Earth's natural satellite. These and numerous other exciting missions are fertile subjects for public education and outreach. NASA's core mission includes engaging the public face of space in many forms and forums. Agency goals include communicating with people across the United States and through international opportunities. NASA has created a culture where communication opportunities are valued avenues to deliver information about scientific findings and exploration possibilities. As this presentation will show, NASA's leaders act as ambassadors in the public arena and set expectations for involvement across their organizations. This presentation will focus on the qualities that NASA leaders cultivate to achieve challenging missions, to expand horizons and question "why". Leaders act with integrity and recognize the power of the team multiplier effect on delivering technical performance within budget and schedule, as well as through participation in education and outreach opportunities. Leaders are responsible for budgeting the resources needed to reach target audiences with compelling, relevant information and serve as role models, delivering key messages to various audiences. Examples that will be featured in this presentation include the Student Launch Projects and Great Moonbuggy race, which reach hundreds of students who are a promising pipeline for new scientists and engineers for a new generation of discovery. The popular Exploration Experience trailer is an interactive-exhibit environment that travels across the United States, conveying the innovation necessary for space travel and the wonder of discovery that comes from viewing our planet as part of the larger space-scape.

Dumbacher, Daniel L.↗

NASA NTRS2009

Leading the Public Face of Space

The National Aeronautics and Space Administration (NASA) is fully committed to sharing the excitement of America's international space missions with its stakeholders, particularly the general public. In 2009, the Space Shuttle delivered astronauts to the Hubble Space Telescope to service that great observatory and to the International Space Station to install the observation platform on the Japanese Kibo laboratory. The Lunar Reconnaissance Orbiter is showing an unprecedented view of the Moon, confirming the presence of hardware left behind during the Apollo missions decades ago and helping scientists better understand Earth's natural satellite. These and numerous other exciting missions are fertile subjects for public education and outreach. NASA's core mission includes engaging the public face of space in many forms and forums. Agency goals include communicating with people across the United States and through international opportunities. NASA has created a culture where communication opportunities are valued avenues to deliver information about scientific findings and exploration possibilities. As this presentation will show, NASA's leaders act as ambassadors in the public arena and set expectations for involvement across their organizations. This presentation will focus on the qualities that NASA leaders cultivate to achieve challenging missions, to expand horizons and question "why". Leaders act with integrity and recognize the power of the team multiplier effect on delivering technical performance within budget and schedule, as well as through participation in education and outreach opportunities. Leaders are responsible for budgeting the resources needed to reach target audiences with compelling, relevant information and serve as role models, delivering key messages to various audiences. Examples that will be featured in this presentation include the Student Launch Projects and Great Moonbuggy race, which reach hundreds of students who are a promising pipeline for new scientists and engineers for a new generation of discovery. The popular Exploration Experience trailer is an interactive-exhibit environment that travels across the United States, conveying the innovation necessary for space travel and the wonder of discovery that comes from viewing our planet as part of the larger space-scape.

Dumbacher, Daniel L.↗

NASA NTRSDate not supplied

X-59 Air Data Probe Calibration Wind Tunnel Test

NASA's aeronautical innovators are working with Lockheed Martin to design and build a supersonic X-plane, the X-59, under the the Low Boom Flight Demonstrator (LBFD) Project, that produces a gentle thump rather than a loud sonic boom. The plane will be used to collect human response data over select U.S. communities. The data from the X-59 test flights will be provided to U.S. and international regulators to potentially allow supersonic flight over land, drastically reducing travel time within the U.S. and around the world. Two wind tunnel tests were conducted in the NASA Glenn Research Center (GRC) 8- by 6-Foot Supersonic Wind Tunnel to calibrate the nose probe for the X-59. The probe was successfully tested and calibrated at 19 Mach numbers between Mach 0.25 and Mach 1.7. Most data were collected using continuous roll angle sweeps at a set Mach number and pitch angle. About 725 high quality data runs were recorded during testing to be used in the calibration of the probe. A backup nose probe was also run through the same test matrix as the primary probe. The probe will be the primary instrument for the flight test of the X-59 for determining angle of attack, angle of sideslip, airspeed, and pressure altitude of the aircraft in flight. Knowing the aircraft's speed and attitude is critical for flight safety and is also critical data for the Sonic Boom mission. Areas of interest for the test were sea level takeoff and landing at Mach 0.2, subsonic cruise at Mach 0.9, and supersonic cruise at Mach 1.4. During Phase I flight testing, the air data nose probe and air data system as a whole will be further calibrated in flight to account for additional installed effects of the airframe on the air data system.

X-59↗

NASA NTRSDate not supplied

X-59 Air Data Probe Calibration Wind Tunnel Test

NASA's aeronautical innovators are working with Lockheed Martin to design and build a supersonic X-plane, the X-59, under the the Low Boom Flight Demonstrator (LBFD) Project, that produces a gentle thump rather than a loud sonic boom. The plane will be used to collect human response data over select U.S. communities. The data from the X-59 test flights will be provided to U.S. and international regulators to potentially allow supersonic flight over land, drastically reducing travel time within the U.S. and around the world. Two wind tunnel tests were conducted in the NASA Glenn Research Center (GRC) 8- by 6-Foot Supersonic Wind Tunnel to calibrate the nose probe for the X-59. The probe was successfully tested and calibrated at 19 Mach numbers between Mach 0.25 and Mach 1.7. Most data were collected using continuous roll angle sweeps at a set Mach number and pitch angle. About 725 high quality data runs were recorded during testing to be used in the calibration of the probe. A backup nose probe was also run through the same test matrix as the primary probe. The probe will be the primary instrument for the flight test of the X-59 for determining angle of attack, angle of sideslip, airspeed, and pressure altitude of the aircraft in flight. Knowing the aircraft's speed and attitude is critical for flight safety and is also critical data for the Sonic Boom mission. Areas of interest for the test were sea level takeoff and landing at Mach 0.2, subsonic cruise at Mach 0.9, and supersonic cruise at Mach 1.4. During Phase I flight testing, the air data nose probe and air data system as a whole will be further calibrated in flight to account for additional installed effects of the airframe on the air data system.

X-59↗

NASA NTRS1999

Investigation Into The Effects of Microsecond Power Line Transients On Line-Connected Capacitors

An investigation was conducted into the effect of power-line transients on capacitors used by NASA and installed on platform primary power inputs to avionics. The purpose was to investigate whether capacitor voltage rating needs to be derated for expected spike potentials. Concerns had been voiced in the past by NASA suppliers that MIL-STD-461 CS06-like requirements were overly harsh and led to physically large capacitors. The author had previously predicted that electrical-switching spike requirements representative of actual power-line transient potentials, durations and source impedance would require no derating. This investigation bore out that prediction. It was further determined that traditional low source impedance CS06-like transients also will not damage a capacitor, although the spikes themselves are not nearly as well filtered. This report should be used to allay fears that CS06-like requirements drive capacitor voltage derating. Only that derating required by the relatively long duration transients in power quality specification need concern the equipment designer.

Javor, Ken↗

NASA NTRS2000

Investigation into the Effects of Microsecond Power Line Transients on Line-Connected Capacitors

An investigation was conducted into the effect of power-line transients on capacitors used by NASA and installed on platform primary power inputs to avionics. The purpose was to investigate whether capacitor voltage ratings needs to be derated for expected spike potentials. Concerns had been voiced in the past by NASA suppliers that MIL-STD-461 CS06-like requirements were overly harsh and led to physically large capacitors. The author had previously predicted that electrical-switching spike requirements representative of actual power-line transient potentials, durations. and source impedance would require no derating. This investigation bore out that prediction. It was further determined that traditional low source impedance CS06-like transients also will not damage a capacitor, although the spikes themselves are not nearly as well filtered. This report should be used to allay fears that CS06-like requirements drive capacitor voltage derating. Only that derating required by the relatively long duration transients in power quality specification need concern the equipment designer.

Javor, K.↗

NASA NTRS2001

Observations of Sea Surface Mean Square Slope During the Southern Ocean Waves Experiment

For the Southern Ocean Waves Experiment (SOWEX), conducted in June 1992 out of Hobart, Tasmania, the NASA Scanning Radar Altimeter (SRA) was shipped to Australia and installed on a CSIRO Fokker F-27 research aircraft instrumented to make comprehensive surface layer measurements of air-sea interaction fluxes. The SRA sweeps a radar beam of P (two-way) half-power width across the aircraft ground track over a swath equal to 0.8 of the aircraft height, simultaneously measuring the backscattered power at its 36 GHz (8.3 mm) operating frequency and the range to the sea surface at 64 cross-track positions. In realtime, the slant ranges are multiplied by the cosine of the off-nadir incidence angles (including the effect of aircraft roll attitude) to determine the vertical distances from the aircraft to the sea surface. These distances are subtracted from the aircraft height to produce a sea-surface elevation map, which is displayed on a monitor in the aircraft to enable real-time assessments of data quality and wave properties. The sea surface mean square slope (mss), which is predominantly caused by the short waves, was determined from the backscattered power falloff with incidence angle measured by the SRA in the plane normal to the aircraft heading. On each flight, data were acquired at 240 m altitude while the aircraft was in a 7 degree roll attitude, interrogating off-nadir incidence angles from -15 degrees through nadir to +29 degrees. The aircraft turned azimuthally through 810 degrees in this attitude, mapping the azimuthal dependence of the backscattered power falloff with incidence angle. Two sets of turning data were acquired on each day, before and after the aircraft measured wind stress at low altitude (12 meters to 65 meters). Wave topography and backscattered power for mss were also acquired during those level flight segments whenever the aircraft altitude was above the SRA minimum range of 35 m. Data were collected over a wide range of wind and sea conditions, from quiescent to gale force winds with 9 meter wave height.

Walsh, E. J.↗

NASA NTRS2010

Improved Hypoxia Modeling for Nutrient Control Decisions in the Gulf of Mexico

As required by the Harmful Algal Bloom and Hypoxia Research Control Act of 1998, the Mississippi River/Gulf of Mexico Watershed Nutrient Task Force issued the 2001 Gulf Hypoxia Action Plan (updated in 2008). In response to the Gulf Hypoxia Action Plan of 2001 (updated in 2008), the EPA Gulf of Mexico Hypoxia Modeling and Monitoring Project has established a detailed model for the Mississippi-Attchafalaya River Basin which provides a capability to forecast the multi-source nutrient loading to the Gulf and the subsequent bio-geochemical processes leading to hypoxic conditions and subsequent effects on Gulf habitats and fisheries. The primary purpose of the EPA model is to characterize the impacts of nutrient management actions, or proposed actions on the spatial and temporal characteristics of the Gulf hypoxic zone. The model is expected to play a significant role in determining best practices and improved strategies for incentivizing nutrient reduction strategies, including installation of on-farm structures to reduce sediment and nutrient runoff, use of cover crops and other agricultural practices, restoration of wetlands and riparian buffers, improved waste water treatment and decreased industrial nitrogen emissions. These decisions are currently made in a fragmented way by federal, state, and local agencies, using a variety of small scale models and limited data. During the past three years, EPA has collected an enormous amount of in-situ data to be used in the model. We believe that the use of NASA satellite data products in the model and for long term validation of the model has the potential to significantly increase the accuracy and therefore the utility of the model for the decision making described above. This proposal addresses the Gulf of Mexico Alliance (GOMA) priority issue of reductions in nutrient inputs to coastal ecosystem. It further directly relates to water quality for healthy beaches and shellfish beds and wetland and coastal conservation restoration.

Habib, Shaid↗

NASA NTRS2005

Evaluation of Thermal Protection Tile Transmissibility for Ground Vibration Test

Transmissibility analyses and tests were conducted on a composite panel with thermal protection system foams to evaluate the quality of the measured frequency response functions. Both the analysis and the test results indicate that the vehicle dynamic responses are fully transmitted to the accelerometers mounted on the thermal protection system in the normal direction below a certain frequency. In addition, the in-plane motions of the accelerometer mounted on the top surface of the thermal protection system behave more actively than those on the composite panel due to the geometric offset of the accelerometer from the panel in the test set-up. The transmissibility tests and analyses show that the frequency response functions measured from the accelerometers mounted on the TPS will provide accurate vehicle responses below 120 Hz for frequency and mode shape identification. By confirming that accurate dynamic responses below a given frequency can be obtained, this study increases the confidence needed for conducting the modal testing, model correlation, and model updating for a vehicle installed with TPS. '

Chung, Y. T.↗

NASA NTRS2004

Gear Performance Improved by Coating

Gears, bearings, and other mechanical elements transmit loads through contacting surfaces. Even if properly designed, manufactured, installed, and maintained, gears and bearings will eventually fail because of the fatigue of the working surfaces. Economical means for extending the fatigue lives of gears and bearings are highly desired, and coatings offer the opportunity to engineer surfaces to extend the fatigue lives of mechanical components. A tungsten-containing diamondlike-carbon coating exhibiting high hardness, low friction, and good toughness was evaluated for application to spur gears. Fatigue testing was done at the NASA Glenn Research Center on both uncoated and coated spur gears. The results showed that the coating extended the surface fatigue lives of the gears by a factor of about 5 relative to the uncoated gears. For the experiments, a lot of spur test gears made from AISI 9310 gear steel were case-carburized and ground to aerospace specifications. The geometries of the 28-tooth, 8-pitch gears were verified as meeting American Gear Manufacturing Association (AGMA) quality class 12. One-half of the gears were randomly selected for coating. The method of coating was selected to achieve desired adherence, toughness, hardness, and low-friction characteristics. First the gears to be coated were prepared by blasting (vapor honing) with Al2O3 particles and cleaning. Then, the gears were provided with a thin adhesion layer of elemental chromium followed by magnetron sputtering of the outer coating consisting of carbon (70 at.%), hydrogen (15 at.%), tungsten (12 at.%), and nickel (3 at.%) (atomic percent at the surface). In total, the coating thickness was about 2.5 to 3 microns. As compared with the steel substrate, the coated surface was harder by a factor of about 2 and had a smaller elastic modulus. All gears were tested using a 5-centistoke synthetic oil, a 10,000-rpm rotation speed, and a hertzian contact stress of at least 1.7 GPa (250 ksi). Tests were run until either surface fatigue occurred or 300 million stress cycles were completed. Tests were run using either a pair of uncoated gears or a pair of coated gears (coated gears mated with uncoated gears were not evaluated). The fatigue test results, shown on Weibull coordinates in the graph, demonstrate that the coating provided substantially longer fatigue lives even though some of the coated gears endured larger stresses. The increase in fatigue life was a factor of about 5 and the statistical confidence for the improvement is high (greater than 99 percent). Examination of the tested gears revealed substantial reductions of total wear for coated gears in comparison to uncoated gears. The coated gear surface topography changed with running, with localized areas of the tooth surface becoming smoother with running. Theories explaining how coatings can extend gear fatigue lives are research topics for coating, tribology, and fatigue specialists. This work was done as a partnership between NASA, the U.S. Army Research Laboratory, United Technologies Research Corporation, and Sikorsky Aircraft.

Krantz, Timothy L.↗