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Sealing efficiency, service life, and seal loading limits of lip seal for rotating shafts are analyzed. Construction of seal and areas of application are described. Specific advantages of improved lip seal over conventional seals are listed.
An abradable buffered labyrinth seal for the control of turbine gas path leakage in a tip-turbine driven lift fan was designed, tested, and analyzed. The seal configuration was not designed to operate in any specific location but was sized to be evaluated in an existing test rig. The final sealing diameter selected was 28 inches. Results of testing indicate that the flow equations predicted seal air flows consistent with measured values. Excellent sealing characteristics of the abradable coating on the stator land were demonstrated when a substantial seal penetration of .030 inch into the land surface was encountered without appreciable wear on the labyrinth knife edges.
Self-acting and hydrodynamic seals are described. The analytical procedures are outlined for obtaining a seal force balance and the operating film thickness. Particular attention is given to primary ring response (seal vibration) to rotating seat face runout. This response analysis revealed three different vibration modes. Proposed applications of self-acting seals in gas turbine engines and in rocket vehicle turbopumps are described. Also experimental data on self-acting face seals operating under simulated gas turbine conditions are given; these data show the feasibility of operating the seal at conditions of 345 newtons per square centimeter (500 psi) and 152 meters per second (500 ft/sec) sliding speed.
Self-acting and hydrodynamic seals are described. The analytical procedures are outlined for obtaining a seal force balance and the operating film thickness. Particular attention is given to primary ring response (seal vibration) to rotating seat face runout. This response analysis revealed three different vibration modes. Proposed applications of self-acting seals in gas turbine engines and in rocket vehicle turbopumps are described. Also experimental data on self-acting face seals operating under simulated gas turbine conditions are given; these data show the feasibility of operating the seal at conditions of 345 newtons per square centimeter (500 psi) and 152 meters per second (500 ft/sec) sliding speed.
Polyimide second-stage rod seals were evaluated to determine their suitability for applications in space station environments. The 6.35-cm (2.5-in.)K-section seal was verified for thermal cycling operation between room temperature and 478 K (400 F) and for operation in a 133 micron PA(0.000001 mm Hg) vacuum environment. The test seal completed the scheduled 96 thermal cycles and 1438 hr in vacuum with external rod seal leakage well within the maximum allowable of two drops per 25 actuation cycles. At program completion, the seals showed no signs of structural degradation. Posttest inspection showed the seals retained a snug fit against the shaft and housing walls, indicating additional wear life capability. Evaluation of a molecular flow section during vacuum testing, to inhibit fluid loss through vaporization, showed it to be beneficial with MIL-H-5606, a petroleum-base fluid, in comparison with MIL-H-83282, a synthetic hydrocarbon-base fluid.
An experimental evaluation of main shaft seals for helicopter gas turbine engines was conducted with shaft speeds to 213 m/s(700 ft/sec), air pressures to 148 N/sq cm (215 psia), and air temperatures to 645 K (675 F). Gas leakage test results indicate that conventional seals will not be satisfactory for high-pressure sealing because of excessive leakage. The self-acting face seal, however, had significantly lower leakage and operated with insignificant wear during a 150-hour endurance test at sliding speeds to 145 m/s (475 ft/sec), air pressures to 124 N/sq cm (180 psia), and air temperatures to 408 K (275 F). Wear measurements indicate that noncontact operation was achieved at shaft speeds of 43,000 rpm. Evaluation of the self-acting circumferential seal was inconclusive because of seal dimensional variations.
A modified circumferential segmented ring seal was designed for direct replacement of a helicopter transmission elastomeric lip seal operating on a shaft diameter of 13.91 centimeters (5.481 in.) at sliding velocities to 52.48 m/sec (10 330 ft/min). The modifications involved the garter spring tension, shaft roundness, seal housing flatness, and pumping grooves to inhibit leakage. Operation of the seals in bench tests under simulated helicopter transmission conditions revealed that the seal leakage rate was within acceptable limits and that the wear rate was negligible. The low leakage and wear rates were confirmed in flight tests of 600 and 175 hours (sliding speed, 48.11 m/sec (9470 ft/min)). An additional 200 hours of air worthiness qualification testing (aircraft tie down) demonstrated that the seal can operate at the advanced sliding conditions of 52.48 m/sec (10 330 ft/min).
The fundamental principles governing dynamic sealing operation are discussed. Different seals are described in terms of these principles. Despite the large variety of detailed construction, there appear to be some basic principles, or combinations of basic principles, by which all seals function, these are presented and discussed. Theoretical and practical considerations in the application of these principles are discussed. Advantages, disadvantages, limitations, and application examples of various conventional and special seals are presented. Fundamental equations governing liquid and gas flows in thin film seals, which enable leakage calculations to be made, are also presented. Concept of flow functions, application of Reynolds lubrication equation, and nonlubrication equation flow, friction and wear; and seal lubrication regimes are explained.
The fundamental principles governing dynamic sealing operation are discussed. Different seals are described in terms of these principles. Despite the large variety of detailed construction, there appear to be some basic principles, or combinations of basic principles, by which all seals function. They are: (1) selection and control of seal geometry, (2) control of leakage fluid properties, and (3) control of forces acting on leakage fluids. Theoretical and practical considerations in the application of these principles are discussed. Advantages, disadvantages, limitations, and application examples of various conventional and special seals are presented. Fundamental equations governing liquid and gas flows in thin-film seals, which enable leakage calculations to be made, are also presented.
Advanced high temperature hydraulic system rod sealing requirements can be met by using seals made of nonelastomeric (plastic) materials in applications where elastomers do not have adequate life. Exploratory seal designs were optimized for advanced applications using machinable polyimide materials. These seals demonstrated equivalent flight hour lives of 12,500 at 350 F and 9,875 at 400 F in advanced hydraulic system simulation. Successful operation was also attained under simulated space shuttle applications; 96 reentry thermal cycles and 1,438 hours of vacuum storage. Tests of less expensive molded plastic seals indicated a need for improved materials to provide equivalent performance to the machined seals.
A method for making a glass-to-metal seal is described. A domed metal enclosure having a machined seal ring is fitted to a glass post machined to a slight taper and to a desired surface finish. The metal part is then heated by induction in a vacuum. As the metal part heats and expands relative to the glass post, the metal seal ring, possessing a higher coefficient of expansion than the glass post, slides down the tapered post. Upon cooling, the seal ring crushes against the glass post forming the seal. The method results in a glass-to-metal seal possessing extremely good leak resistance, while the parts are kept clean and free of the contaminants.
Basic assembly configurations of the mechanical face seal are described and some advantages associated with each are listed. The various forms of seal components are illustrated, and functions pointed out. The technique of seal pressure balancing and its application are described; and the concept of the PV factor, its different forms and limitations are discussed. Brief attention is given to seal lubrication since it is covered in detail in a companion paper. Finally, the operating conditions for various applications of low pressure seals (aircraft transmissions) are listed, and the seal failure mode of a particular application is discussed.
A new seal concept, the negative lift circumferential type seal, was evaluated under simulated helicopter transmission conditions. The bore of the circumferential seal contains step type geometry which produces a negative lift that urges the sealing segments towards the shaft surface. The seal size was a 2.5 inch bore and the test speeds were 7000 and 14,250 rpm. During the 300 hour test at typical transmission seal pressure (to 2 psig) the leakage was within acceptable limits and generally less than 0.1 cc/hour during the last 150 hours of testing. The wear to the carbon segments during the 300 hours was negligible.
A survey of gas path seals is presented with particular attention given to sealing clearance effects on engine component efficiency. The effects on compressor pressure ratio and stall margin are pointed out. Various case-rotor relative displacements, which affect gas path seal clearances, are identified. Forces produced by nonuniform sealing clearances and their effect on rotor stability are discussed qualitatively, and recent work on turbine-blade-tip sealing for high temperature is described. The need for active clearance control and for engine structural analysis is discussed. The functions of the internal-flow system and its seals are reviewed.
Development of the plasma sprayed graded, layered ZRO2/CoCrAlY seal system for gas turbine engine blade tip seal applications up to 1589 K (2400 F) surface temperature was continued. The effect of changing ZRO2/CoCrAlY ratios in the intermediate layers on thermal stresses was evaluated analytically with the goal of identifying the materials combinations which would minimize thermal stresses in the seal system. Three methods of inducing compressive residual stresses in the sprayed seal materials to offset tensile thermal stresses were analyzed. The most promising method, thermal prestraining, was selected based upon potential, feasibility and complexity considerations. The plasma spray equipment was modified to heat, control and monitor the substrate temperature during spraying. Specimens were fabricated and experimentally evaluated to: (1) substantiate the capability of the thermal prestrain method to develop compressive residual stresses in the sprayed structure and (2) define the effect of spraying on a heated substate on abradability, erosion and thermal shock characteristics of the seal system. Thermal stress analysis, including residual stresses and material properties variations, was performed and correlated with thermal shock test results. Seal system performance was assessed and recommendations for further development were made.
Radial forces on the primary seal ring of a flat misaligned seal are analyzed, taking into account the radial variation in seal clearance. An analytical solution for both hydrostatic and hydrodynamic effects is presented that covers the whole range from zero to full angular misalignment. The net radial force on the primary seal ring is always directed so as to produce a radial eccentricity which generates inward pumping. Although the radial force is usually very small, in some cases it may be one of the reasons for excessive leakage through both the primary and secondary seals of a radial face seal.
Survey of gas path seals is presented with particular attention given to sealing clearance effects on engine component efficiency. The effects on compressor pressure ratio and stall margin are pointed out. Various case-rotor relative displacements, which affect gas path seal clearances, are identified. Forces produced by nonuniform sealing clearances and their effect on rotor stability are discussed qualitatively, and recent work on turbine-blade-tip sealing for high temperatures is described. The need for active clearance control and for engine structural analysis is discussed. The functions of the internal-flow system and its seals are reviewed.
Gas path seals are discussed with emphasis on sealing clearance effects on engine component efficiency, compressor pressure ratio, and stall margin. Various case-rotor relative displacements, which affect gas path seal clearances, are identified. Forces produced by nonuniform sealing clearances and their effect on rotor stability are examined qualitatively, and recent work on turbine-blade-tip sealing for high temperatures is described. The need for active clearance control and for engine structural analysis is discussed. The functions of the internal-flow system and its seals are reviewed.