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NASA NTRS1981

Contact resistivities of sputtered TiN and Ti-TiN metallizations on solar-cell-type-silicon

The resistivities of TiN and Ti-TiN contacts on a shallow junction solar-cell-type silicon substrate have been determined by the method of the transmission line model. The contacts investigated are shown to be suitable for standard solar cells from an electrical point of view. Contact resistivity values of the order of 0.0001 ohm/sq cm as obtained for the n(+)Si-TiSi2-TiN contact system may be acceptable for concentrations up to 100 times, but lower values are necessary beyond this point.

Maenpaa, M.↗

NASA NTRS2024

On the Role of Friction and Particle Size Distribution in Granular Packings

Packing of particles in a disordered arrangement has tremendous significance in both condensed matter physics and engineering applications. The last three decades have seen remarkable progress in our understanding of the physics of granular packings that has been largely facilitated by a rapid growth in the power of modern computers. Although granular packings are ubiquitous in diverse natural settings, from clogging of powders in hoppers to the crowding of living cells, a significant motivation for modeling granular packings has emerged from a proposal that the transition from a fluid-like state to a solid-like state of a granular material upon increasing volume fraction, called jamming, is intimately related to the origins of glass transition in thermal systems. As such, a majority of modeling efforts have focused on the jamming behavior of an idealized granular material: frictionless, monodisperse sphere. While such studies have illuminated the rich physics of jamming, granular materials in nature and engineering practice are rarely frictionless or monodisperse. The analogous research on the packing of these ‘real-world’ granular materials is still not fully developed. Besides requiring the exploration of a huge parameter space, three key computational considerations have inhibited their modeling: (i) traditional computational methods are not adept at simulating mechanically-stable packings of frictional particles near the jamming transition; (ii) standard algorithms of contact detection in discrete element methods are impractical to simulate granular packings with a wide distribution of particle sizes; (iii) a lack of well-established contact mechanics models of friction that can accurately reproduce experimental data. This chapter will review the latest computational advances to simulate the jamming of size-dispersed frictional particles, and describe the rich microstructural diversity that emerges in their packings.

granular↗

NASA NTRS1980

Hektor - Nature and origin of a binary asteroid

It is argued that the elongated single body model (Dunlap and Gehrels, 1969) which reproduces the rotational light curve of 624 Hektor is unstable with respect to binary fission. It is shown that a contact binary model with ellipsoidal components of equilibrium shape matches the observed amplitude. Hektor's bulk density is inferred to be about 2.5 g/cu cm.

Weidenschilling, S. J.↗

NASA NTRS1983

Non-Newtonian Fluid Model Incorporated into Elastohydrodynamic Lubrication of Rectangular Contacts

A procedure is outlined for the numerical solution of the complete elastohydrodynamic lubrication of rectangular contacts incorporating a non-Newtonian fluid model. The approach uses a Newtonian model as long as the shear stress is less than a limiting shear stress. If the shear stress exceeds the limiting value, the shear stress is set equal to the limiting value. The numerical solution requires the coupled solution of the pressure, film shape, and fluid rheology equations from the inlet to the outlet. Isothermal and no-side-leakage assumptions were imposed in the analysis. The influence of dimensionless speed, load, materials, and sliding velocity and limiting-shear-strength proportionality constant on dimensionless minimum film thickness was investigated. Fourteen cases were used in obtaining the minimum-film-thickness equation for an elastohydrodynamically lubricated rectangular contact incorporating a non-Newtonian fluid model. Computer plots are also presented that indicate in detail pressure distribution, film shape, shear stress at the surfaces, and flow throughout the conjunction.

Jacobson, B. O.↗

NASA NTRS1984

Non-Newtonian fluid model incorporated into elastohydrodynamic lubrication of rectangular contacts

Jacobson, B. O.↗

NASA NTRS2019

Real-Time Modeling of Thermal Interactions in Cryogenic Ball Bearings

Based on the integration of classical differential equations of motion of bearing elements, a real-time dynamic simulation of ball bearing performance is coupled with simultaneous modeling of thermal interactions between the bearing elements. The transient heat generations are time averaged over a significantly larger time step before they are used to compute the changes in bearing temperature fields. Such an averaging algorithm eliminates the numerical difficulties associated with simultaneous integration of mechanical thermal differential equations with vastly different time scales. Under stable operation, the step change in temperatures at each thermal time step converges to a steady-state solution. Following is a list of accomplishments in the present investigation: (1) A real-time dynamic performance of both 440C and hybrid ball bearings in a LOX environment is modeled in both transient and steady-state time domains, as the inner race accelerates to a prescribed operating speed. (2) The frictional interactions at the ball to race contacts are modeled by experimentally measured traction coefficients as a function of slide-to-roll ratios. (3) Bearing heat generation, as defined by the heat transferred to circulating LOX, is validated against experimental values determined by measured LOX temperatures under prescribed pressures and flow rates. The predicted heat generation is in good agreement with the experimental values. (4) The steady-state solutions are shown to be independent of initial conditions. This establishes convergence of the numerical integration of a differential equation of motion of the bearing elements. (5) Churning and drag losses in the circulating LOX constitutes the majority of bearing heat generation under the experimental test conditions. (6) The heat dissipated in frictional interactions in hybrid bearings is significantly lower in hybrid bearings in comparison to that simulated in all-steel bearings, while the churning and drag losses are relatively unchanged.

Gupta, P. K.↗

NASA NTRS2019

An Analytic Model for Estimating the First Contact Resistance Needed to Avoid Damaging ESD During Spacecraft Docking in GEO

NASA’s Gateway program will involve spacecraft (s/c) docking in the outer radiation belt in order to transfer Gateway elements between s/c for transport to lunar orbit. The charging of these s/c to different potentials prior to docking raises the possibility of a damaging electrostatic discharge (ESD) at the time of first contact between the s/c. A proposed mitigation strategy is for first contact to occur prior to docking through a resistor with resistance R that would lower the potential difference at an optimal rate to a sufficiently low value to prevent ESD damage. The coupling of s/c by a resistor can be modeled by SPIS, but for realistic two s/c models SPIS can take hours to simulate the evolution of the s/c surface charges and potentials to an equilibrium state. Our objective is to develop a simpler model of s/c resistive coupling that runs orders of magnitude faster while providing useful first design estimates of the time variation of the s/c potentials, current through the resistor, and how these vary with R and s/c configuration This configuration is defined by the relative separation and orientation of the s/c, and their solar illumination. The configuration and geometry of the s/c determine their capacitive coupling. The s/c capacitances are computed using Nascap-2K. This poster presents the first version of such a model, and initial tests.

Goodman, Michael L.↗

NASA NTRS2010

Charge-Spot Model for Electrostatic Forces in Simulation of Fine Particulates

The charge-spot technique for modeling the static electric forces acting between charged fine particles entails treating electric charges on individual particles as small sets of discrete point charges, located near their surfaces. This is in contrast to existing models, which assume a single charge per particle. The charge-spot technique more accurately describes the forces, torques, and moments that act on triboelectrically charged particles, especially image-charge forces acting near conducting surfaces. The discrete element method (DEM) simulation uses a truncation range to limit the number of near-neighbor charge spots via a shifted and truncated potential Coulomb interaction. The model can be readily adapted to account for induced dipoles in uncharged particles (and thus dielectrophoretic forces) by allowing two charge spots of opposite signs to be created in response to an external electric field. To account for virtual overlap during contacts, the model can be set to automatically scale down the effective charge in proportion to the amount of virtual overlap of the charge spots. This can be accomplished by mimicking the behavior of two real overlapping spherical charge clouds, or with other approximate forms. The charge-spot method much more closely resembles real non-uniform surface charge distributions that result from tribocharging than simpler approaches, which just assign a single total charge to a particle. With the charge-spot model, a single particle may have a zero net charge, but still have both positive and negative charge spots, which could produce substantial forces on the particle when it is close to other charges, when it is in an external electric field, or when near a conducting surface. Since the charge-spot model can contain any number of charges per particle, can be used with only one or two charge spots per particle for simulating charging from solar wind bombardment, or with several charge spots for simulating triboelectric charging. Adhesive image-charge forces acting on charged particles touching conducting surfaces can be up to 50 times stronger if the charge is located in discrete spots on the particle surface instead of being distributed uniformly over the surface of the particle, as is assumed by most other models. Besides being useful in modeling particulates in space and distant objects, this modeling technique is useful for electrophotography (used in copiers) and in simulating the effects of static charge in the pulmonary delivery of fine dry powders.

Walton, Otis R.↗

NASA NTRS2019

An Analytic Model for Estimating the First Contact Resistance Needed to Avoid Damaging ESD During Spacecraft Docking in GEO

NASA’s Gateway program is to involve spacecraft (s/c) docking in the outer radiation belt in order to transfer Gateway elements between s/c for transport to lunar orbit. The charging of these s/c to different potentials prior to docking raises the possibility of a damaging electrostatic discharge (ESD) at the time of first contact between the s/c. A proposed mitigation strategy is for first contact to occur prior to docking through a resistor with resistance R that would lower the potential difference at an optimal rate to a sufficiently low value to prevent a damaging ESD. The coupling of s/c by a resistor can be modeled by SPIS (Spacecraft Plasma Interaction System), but for realistic two s/c models SPIS can take hours to simulate the evolution of the s/c surface charges and potentials to an equilibrium state. Our objective is to develop a simpler model of s/c resistive coupling that runs orders of magnitude faster while providing useful first design estimates of the time variation of the s/c potentials, current through the resistor, and how these vary with R and s/c configuration. This configuration is defined by the relative separation and orientation of the s/c, and their solar illumination. The configuration and geometry of the s/c determine their capacitive coupling. The s/c capacitances are computed using Nascap-2K. This abstract and the associated poster describe the first version of such a model, and initial tests.

Goodman, Michael L.↗

NASA NTRS1986

A heater made from graphite composite material for potential deicing application

A surface heater was developed using a graphite fiber-epoxy composite as the heating element. This heater can be thin, highly electrically and thermally conductive, and can conform to an irregular surface. Therefore it may be used in an aircraft's thermal deicing system to quickly and uniformly heat the aircraft surface. One-ply of unidirectional graphite fiber-epoxy composite was laminated between two plies of fiber glass-epoxy composite, with nickel foil contacting the end portions of the composite and partly exposed beyond the composites for electrical contact. The model heater used brominated P-100 fibers from Amoco. The fiber's electrical resistivity, thermal conductivity and density were 50 micro ohms per centimeter, 270 W/m-K and 2.30 gm/cubic cm, respectively. The electricity was found to penetrate through the composite in the transverse direction to make an acceptably low foil-composite contact resistance. When conducting current, the heater temperature increase reached 50 percent of the steady state value within 20 sec. There was no overheating at the ends of the heater provided there was no water corrosion. If the foil-composite bonding failed during storage, liquid water exposure was found to oxidize the foil. Such bonding failure may be avoided if perforated nickel foil is used, so that the composite plies can bond to each other through the perforated holes and therefore lock the foil in place.

Hung, C. C.↗

NASA NTRS1987

A heater made from graphite composite material for potential deicing application

A surface heater was developed using a graphite fiber-epoxy composite as the heating element. This heater can be thin, highly electrically and thermally conductive, and can conform to an irregular surface. Therefore it may be used in an aircraft's thermal deicing system to quickly and uniformly heat the aircraft surface. One-ply of unidirectional graphite fiber-epoxy composite was laminated between two plies of fiber glass-epoxy composite, with nickel foil contacting the end portions of the composite and partly exposed beyond the composites for electrical contact. The model heater used brominated P-100 fibers from Amoco. The fiber's electrical resistivity, thermal conductivity and density were 50 micro ohms per centimenter, 270 W/m-K and 2.30 gm/cubic cm, respectively. The electricity was found to penetrate through the composite in the transverse direction to make an acceptably low foil-composite contact resistance. When conducting current, the heater temperature increase reached 50 percent of the steady state value within 20 sec. There was no overheating at the ends of the heater provided there was no water corrosion. If the foil-composite bonding failed during storage, liquid water exposure was found to oxidize the foil. Such bonding failure may be avoided if perforated nickel foil is used, so that the composite plies can bond to each other through the perforated holes and therefore lock the foil in place.

Hung, Ching-Cheh↗

NASA NTRS1987

Mechanisms of rolling contact spalling

The results of a study aimed at analyzing the mechanical material interactions responsible for rolling contact spalling of the 440 C steel, high pressure oxygen turbopump bearings are presented. A coupled temperature displacement finite element analysis of the effects of friction heating under the contact is presented. The contact is modelled as a stationary, heat generating, 2 dimensional indent in an elastic perfectly plastic half-space with heat fluxes up to 8.6 x 10000 KW/m sq comparable to those generated in the bearing. Local temperatures in excess of 1000 C are treated. The calculations reveal high levels of residual tension after the contact is unloaded and cools. Efforts to promote Mode 2/Mode 3 fatigue crack growth under cyclic torsion in hardened 440 C steel are described. Spalls produced on 440 C steel by a 3 ball/rod rolling contact testing machine were studied with scanning microscopy. The shapes of the cyclic, stress strain hysteresis loops displayed by hardened 440 C steel in cyclic torsion at room temperature are defined for the plastic strain amplitudes encountered in rolling/sliding contact. Results of these analyses are discussed in detail.

Kumar, A. M.↗

NASA NTRS2014

Launch Load Resistant Spacecraft Mechanism Bearings Made From NiTi Superelastic Intermetallic Materials

Compared to conventional bearing materials (tool steel and ceramics), emerging Superelastic Intermetallic Materials (SIMs), such as 60NiTi, have significantly lower elastic modulus and enhanced strain capability. They are also immune to atmospheric corrosion (rusting). This offers the potential for increased resilience and superior ability to withstand static indentation load without damage. In this paper, the static load capacity of hardened 60NiTi 50mm bore ball-bearing races are measured to correlate existing flat-plate indentation load capacity data to an actual bearing geometry through the Hertz stress relations. The results confirmed the validity of using the Hertz stress relations to model 60NiTi contacts; 60NiTi exhibits a static stress capability (3.1GPa) between that of 440C (2.4GPa) and REX20 (3.8GPa) tool steel. When the reduced modulus and extended strain capability are taken into account, 60NiTi is shown to withstand higher loads than other bearing materials. To quantify this effect, a notional space mechanism, a 5kg mass reaction wheel, was modeled with respect to launch load capability when supported on 440C, 60NiTi and REX20 tool steel bearings. For this application, the use of REX20 bearings increased the static load capability of the mechanism by a factor of three while the use of 60NiTi bearings resulted in an order of magnitude improvement compared to the baseline 440C stainless steel bearings.

metals↗

NASA NTRS2014

Launch Load Resistant Spacecraft Mechanism Bearings Made From NiTi Superelastic Intermetallic Materials

bearings↗

NASA NTRS1978

Investigations of lubricant rheology as applied to elastohydrodynamic lubrication

Measurements of lubricant shear rheological behavior in the amorphous solid region and near the liquid-solid transition are reported. Elastic, plastic and viscous behavior was observed. A shear rheological model based on primary laboratory data is proposed for concentrated contact lubrication. The model is a Maxwell model modified with a limiting shear stress. Three material properties are required: low shear stress viscosity, limiting elastic shear modulus, and the limiting shear stress the material can withstand. All three are functions of temperature and pressure. In applying the model to EHD contacts the predicted response possesses the characteristics expected from several experiments reported in the literature.

Bair, S.↗

NASA NTRS2014

Launch Load Resistant Spacecraft Mechanism Bearings Made From NiTi Superelastic Intermetallic Materials

Compared to conventional bearing materials (tool steel and ceramics), emerging Superelastic Intermetallic Materials (SIMs), such as 60NiTi, have significantly lower elastic modulus and enhanced strain capability. They are also immune to atmospheric corrosion (rusting). This offers the potential for increased resilience and superior ability to withstand static indentation load without damage. In this paper, the static load capacity of hardened 60NiTi 50-mm-bore ball bearing races are measured to correlate existing flat-plate indentation load capacity data to an actual bearing geometry through the Hertz stress relations. The results confirmed the validity of using the Hertz stress relations to model 60NiTi contacts; 60NiTi exhibits a static stress capability (approximately 3.1 GPa) between that of 440C (2.4 GPa) and REX20 (3.8 GPa) tool steel. When the reduced modulus and extended strain capability are taken into account, 60NiTi is shown to withstand higher loads than other bearing materials. To quantify this effect, a notional space mechanism, a 5-kg mass reaction wheel, was modeled with respect to launch load capability when supported on standard (catalogue geometry) design 440C; 60NiTi and REX20 tool steel bearings. For this application, the use of REX20 bearings increased the static load capability of the mechanism by a factor of three while the use of 60NiTi bearings resulted in an order of magnitude improvement compared to the baseline 440C stainless steel bearings

DellaCorte, Christopher↗

NASA NTRS2007

Robustness of Modeling of Out-of-Service Gas Mechanical Face Seal

Gas lubricated mechanical face seal are ubiquitous in many high performance applications such as compressors and gas turbines. The literature contains various analyses of seals having orderly face patterns (radial taper, waves, spiral grooves, etc.). These are useful for design purposes and for performance predictions. However, seals returning from service (or from testing) inevitably contain wear tracks and warped faces that depart from the aforementioned orderly patterns. Questions then arise as to the heat generated at the interface, leakage rates, axial displacement and tilts, minimum film thickness, contact forces, etc. This work describes an analysis of seals that may inherit any (i.e., random) face pattern. A comprehensive computer code is developed, based upon the Newton- Raphson method, which solves for the equilibrium of the axial force and tilting moments that are generated by asperity contact and fluid film effects. A contact mechanics model is incorporated along with a finite volume method that solves the compressible Reynolds equation. Results are presented for a production seal that has sustained a testing cycle.

Green, Itzhak↗

NASA NTRS2016

An Efficient Ray-Tracing Method for Determining Terrain Intercepts in EDL Simulations

The calculation of a ray's intercept from an arbitrary point in space to a prescribed surface is a common task in computer simulations. The arbitrary point often represents an object that is moving according to the simulation, while the prescribed surface is fixed in a defined frame. For detailed simulations, this surface becomes complex, taking the form of real-world objects such as mountains, craters or valleys which require more advanced methods to accurately calculate a ray's intercept location. Incorporation of these complex surfaces has commonly been implemented in graphics systems that utilize highly optimized graphics processing units to analyze such features. This paper proposes a simplified method that does not require computationally intensive graphics solutions, but rather an optimized ray-tracing method for an assumed terrain dataset. This approach was developed for the Mars Science Laboratory mission which landed on the complex terrain of Gale Crater. First, this paper begins with a discussion of the simulation used to implement the model and the applicability of finding surface intercepts with respect to atmosphere modeling, altitude determination, radar modeling, and contact forces influencing vehicle dynamics. Next, the derivation and assumptions of the intercept finding method are presented. Key assumptions are noted making the routines specific to only certain types of surface data sets that are equidistantly spaced in longitude and latitude. The derivation of the method relies on ray-tracing, requiring discussion on the formulation of the ray with respect to the terrain datasets. Further discussion includes techniques for ray initialization in order to optimize the intercept search. Then, the model implementation for various new applications in the simulation are demonstrated. Finally, a validation of the accuracy is presented along with the corresponding data sets used in the validation. A performance summary of the method will be shown using the analysis from the Mars Science Laboratory's terminal descent sensing model. Alternate uses will also be shown for determining horizon maps and orbiter set times.

Shidner, Jeremy D.↗