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At least 1,351 records · Page 75

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NASA NTRS2000

The Effect of Stress and TiC Coated Balls on Lifetime of a Perfluoropolyalkylether Using a Vacuum Rolling Contact Tribometer

A vacuum spiral orbit tribometer (SOT) was used to determine the relative lifetimes of a branched perfluoropolyalkylether (PFPAE) on 440 C stainless steel. The effect of varying the mean Hertzian stress (0.75, 1.0, 1.5 and 2.0 GPa) and the use of TiC coated balls on lubricant lifetime was studied. Other conditions included: approx. 100 rpm, approx. 50 micro-g of lubricant, an initial vacuum level of less than 1.3 x 10(exp -6) Pa (less than 10 x 10(exp -8) Torr), and room temperature (approx. 23 C). Increasing the mean Hertzian stress from 0.75 to 2.0 GPa results in an exponential decrease in lubricant lifetime for both material combinations. However, substituting a TiC ball for the 440 C ball quadrupled lifetime at low stress levels (0.75 and 1.0 GPa) and doubled life at higher stresses (1.5 and 2.0 GPa), The reduced reactivity of the TiC surface with the PFPAE lubricant is considered to be the reason for this enhancement. Decreasing lifetime with increasing stress levels correlated well with energy dissipation calculations.

Jones, William R., Jr.↗

NASA NTRS2001

Oil-Free Turbomachinery Being Developed

NASA and the Army Research Laboratory (ARL) along with industry and university researchers, are developing Oil-Free technology that will have a revolutionary impact on turbomachinery systems used in commercial and military applications. System studies have shown that eliminating an engine's oil system can yield significant savings in weight, maintenance, and operational costs. The Oil-Free technology (foil air bearings, high-temperature coatings, and advanced modeling) is being developed to eliminate the need for oil lubrication systems on high-speed turbomachinery such as turbochargers and gas turbine engines that are used in aircraft propulsion systems. The Oil-Free technology is enabled by recent breakthroughs in foil bearing load capacity, solid lubricant coatings, and computer-based analytical modeling. During the past fiscal year, a U.S. patent was awarded for the NASA PS300 solid lubricant coating, which was developed at the NASA Glenn Research Center. PS300 has enabled the successful operation of foil air bearings to temperatures over 650 C and has resulted in wear lives in excess of 100,000 start/stop cycles. This leapfrog improvement in performance over conventional solid lubricants (limited to 300 C) creates new application opportunities for high-speed, high-temperature Oil-Free gas turbine engines. On the basis of this break-through coating technology and the world's first successful demonstration of an Oil-Free turbocharger in fiscal year 1999, industry is partnering with NASA on a 3-year project to demonstrate a small, Oil-Free turbofan engine for aeropropulsion.

DellaCorte, Christopher↗

NASA NTRS2005

Analytic Modeling of the Hydrodynamic, Thermal, and Structural Behavior of Foil Thrust Bearings

A simulation and modeling effort is conducted on gas foil thrust bearings. A foil bearing is a self acting hydrodynamic device capable of separating stationary and rotating components of rotating machinery by a film of air or other gaseous lubricant. Although simple in appearance these bearings have proven to be complicated devices in analysis. They are sensitive to fluid structure interaction, use a compressible gas as a lubricant, may not be in the fully continuum range of fluid mechanics, and operate in the range where viscous heat generation is significant. These factors provide a challenge to the simulation and modeling task. The Reynolds equation with the addition of Knudsen number effects due to thin film thicknesses is used to simulate the hydrodynamics. The energy equation is manipulated to simulate the temperature field of the lubricant film and combined with the ideal gas relationship, provides density field input to the Reynolds equation. Heat transfer between the lubricant and the surroundings is also modeled. The structural deformations of the bearing are modeled with a single partial differential equation. The equation models the top foil as a thin, bending dominated membrane whose deflections are governed by the biharmonic equation. A linear superposition of hydrodynamic load and compliant foundation reaction is included. The stiffness of the compliant foundation is modeled as a distributed stiffness that supports the top foil. The system of governing equations is solved numerically by a computer program written in the Mathematica computing environment. Representative calculations and comparisons with experimental results are included for a generation I gas foil thrust bearing.

Bruckner, Robert J.↗

NASA NTRS2008

Mars Science Laboratory Rover Mobility Bushing Development

NASA s Mars Science Laboratory (MSL) Project will send a six-wheeled rover to Mars in 2009. The rover will carry a scientific payload designed to search for organic molecules on the Martian surface during its primary mission. This paper describes the development and testing of a bonded film lubricated bushing system to be used in the mobility system of the rover. The MSL Rover Mobility System contains several pivots that are tightly constrained with respect to mass and volume. These pivots are also exposed to relatively low temperatures (-135 C) during operation. The combination of these constraints led the mobility team to consider the use of solid film lubricated metallic bushings and dry running polymeric bushings in several flight pivot applications. A test program was developed to mitigate the risk associated with using these materials in critical pivots on the MSL vehicle. The program was designed to characterize bushing friction and wear performance over the expected operational temperature range (-135 C to +70 C). Seven different bushing material / lubricant combinations were evaluated to aid in the selection of the final flight pivot bushing material / lubricant combination.

Riggs, Benjamin↗

NASA NTRS2008

Evaluation of Vapor Pressure and Ultra-High Vacuum Tribological Properties of Ionic Liquids (2) Mixtures and Additives

Ionic liquids are salts, many of which are typically viscous fluids at room temperature. The fluids are characterized by negligible vapor pressures under ambient conditions. These properties have led us to study the effectiveness of ionic liquids containing both organic cations and anions for use as space lubricants. In the previous paper we have measured the vapor pressure and some tribological properties of two distinct ionic liquids under simulated space conditions. In this paper we will present vapor pressure measurements for two new ionic liquids and friction coefficient data for boundary lubrication conditions in a spiral orbit tribometer using stainless steel tribocouples. In addition we present the first tribological data on mixed ionic liquids and an ionic liquid additive. Post mortem infrared and Raman analysis of the balls and races indicates the major degradation pathway for these two organic ionic liquids is similar to those of other carbon based lubricants, i.e. deterioration of the organic structure into amorphous graphitic carbon. The coefficients of friction and lifetimes of these lubricants are comparable to or exceed these properties for several commonly used space oils.

Morales, Wilfredo↗

NASA NTRS2007

Spiral Orbit Tribometer

The spiral orbit tribometer (SOT) bridges the gap between full-scale life testing and typically unrealistic accelerated life testing of ball-bearing lubricants in conjunction with bearing ball and race materials. The SOT operates under realistic conditions and quickly produces results, thereby providing information that can guide the selection of lubricant, ball, and race materials early in a design process. The SOT is based upon a simplified, retainerless thrust bearing comprising one ball between flat races (see figure). The SOT measures lubricant consumption and degradation rates and friction coefficients in boundary lubricated rolling and pivoting contacts. The ball is pressed between the lower and upper races with a controlled force and the lower plate is rotated. The combination of load and rotation causes the ball to move in a nearly circular orbit that is, more precisely, an opening spiral. The spiral s pitch is directly related to the friction coefficient. At the end of the orbit, the ball contacts the guide plate, restoring the orbit to its original radius. The orbit is repeatable throughout the entire test. A force transducer, mounted in-line with the guide plate, measures the force between the ball and the guide plate, which directly relates to the friction coefficient. The SOT, shown in the figure, can operate in under ultra-high vacuum (10(exp -9) Torr) or in a variety of gases at atmospheric pressure. The load force can be adjusted between 45 and 450 N. By varying the load force and ball diameter, mean Hertzian stresses between 0.5 and 5.0 GPa can be obtained. The ball s orbital speed range is between 1 and 100 rpm.

Pepper, Stephen V.↗

NASA NTRS2010

Test Validation of the Repair to the Space Station Solar Alpha Rotary Joint (SARJ)

The SARJ LITE (Lubrication Interval Test) test rig was built as a method to evaluate the performance of the grease repair on the Starboard SARJ of the International Space Station(ISS). The on-orbit SARJ was temporarily parked after receiving significant degradation on one of its race ring nitrided surfaces as a result of inadequate lubrication ( high dry contact friction) and unaccounted for roller traction kinematics. In a scaled down rig, flight like roller bearings were preloaded and cycled on a nitrided 15-5 race surface. Grease was added to the track and with instrumentation monitoring performance, trending data will be extracted and used to determine lubrication intervals for both Port and Starboard ISS SARJ's. The grease lubrication was found to be effective in eliminating the high friction that contributed to the on-orbit race degradation.

Allmon, Curtis↗

NASA NTRS2005

High-Temperature, High-Load-Capacity Radial Magnetic Bearing

A radial heteropolar magnetic bearing capable of operating at a temperature as high as 1,000 F (=540 C) has been developed. This is a prototype of bearings for use in gas turbine engines operating at temperatures and speeds much higher than can be withstood by lubricated rolling-element bearings. It is possible to increase the maximum allowable operating temperatures and speeds of rolling-element bearings by use of cooling-air systems, sophisticated lubrication systems, and rotor-vibration- damping systems that are subsystems of the lubrication systems, but such systems and subsystems are troublesome. In contrast, a properly designed radial magnetic bearing can suspend a rotor without contact, and, hence, without need for lubrication or for cooling. Moreover, a magnetic bearing eliminates the need for a separate damping system, inasmuch as a damping function is typically an integral part of the design of the control system of a magnetic bearing. The present high-temperature radial heteropolar magnetic bearing has a unique combination of four features that contribute to its suitability for the intended application: 1. The wires in its electromagnet coils are covered with an insulating material that does not undergo dielectric breakdown at high temperature and is pliable enough to enable the winding of the wires to small radii. 2. The processes used in winding and potting of the coils yields a packing factor close to 0.7 . a relatively high value that helps in maximizing the magnetic fields generated by the coils for a given supplied current. These processes also make the coils structurally robust. 3. The electromagnets are of a modular C-core design that enables replacement of components and semiautomated winding of coils. 4. The stator is mounted in such a manner as to provide stable support under radial and axial thermal expansion and under a load as large as 1,000 lb (.4.4 kN).

Provenza, Andrew↗

NASA NTRS2015

Friction and Wear Management Using Solvent Partitioning of Hydrophilic-Surface-Interactive Chemicals Contained in Boundary Layer-Targeted Emulsions

Lubrication additives of the current invention require formation of emulsions in base lubricants, created with an aqueous salt solution plus a single-phase compound such that partitioning within the resulting emulsion provides thermodynamically targeted compounds for boundary layer organization thus establishing anti-friction and/or anti-wear. The single-phase compound is termed "boundary layer organizer", abbreviated BLO. These emulsion-contained compounds energetically favor association with tribologic surfaces in accord with the Second Law of Thermodynamics, and will organize boundary layers on those surfaces in ways specific to the chemistry of the salt and BLO additives. In this way friction modifications may be provided by BLOs targeted to boundary layers via emulsions within lubricating fluids, wherein those lubricating fluids may be water-based or oil-based.

Richmond, Robert Chaffee↗

NASA NTRS1961

Friction, Wear, and Evaporation Rates of Various Materials in Vacuum to 10(exp -7) mm Hg

The requirements for bearings and seals to operate in the environment of space dictate a new area for lubrication research. The low ambient pressures encountered in space can be expected to influence the behavior of oil, grease, and solid-film lubricants. The property of these materials most significantly affected by low ambient pressures is the evaporation rate. Various investigators have therefore measured the evaporation rates of oils and greases in vacuum as one method of establishing their relative merit for space applications (1-3). The results of this work have given some indication as to the oils and greases with the greatest stability at reduced ambient pressures. Only limited experimental work, however, has been reported in the literature for inorganic solids and soft metals which have potential use as solid lubricant films or coatings for hard alloy substrates [e.g. Reference ( 4 )]. In general, the evaporation rates of these materials would be lower than those of oils and greases. These films might therefore be very attractive as lubricants for high vacuum service.

Buckley, Donald H.↗

NASA NTRS2017

Friction and Wear Modifiers Using Solvent Partitioning of Hydrophilic Surface-Interactive Chemicals Contained in Boundary Layer-Targeted Emulsions

A wear and/or friction reducing additive for a lubricating fluid in which the additive is a combination of a moderately hydrophilic single-phase compound and an anti-wear and/or anti-friction aqueous salt solution. The aqueous salt solution produces a coating on boundary layer surfaces. The lubricating fluid can be an emulsion-free hydrophobic oil, hydraulic fluid, antifreeze, water, or a water-based lubricant. Preferably, the moderately hydrophilic single-phase compound is sulfonated castor oil and the aqueous salt solution additionally contains boric acid and zinc oxide. The emulsions produced by the aqueous salt solutions, the moderately hydrophilic single-phase compounds, or the combination thereof provide targeted boundary layer organizers that significantly enhance the anti-wear and/or anti-friction properties of the base lubricant by decreasing wear and/or friction of sliding and/or rolling surfaces at boundary layers.

Richmond, Robert Chaffee↗

DOE OSTI2023

A Revised International Standard for Gearboxes in Wind Turbine Systems

Gearbox and wind turbine design and application standards have contributed significantly to improvements in reliability over the past two decades. The International Electrotechnical Commission (IEC) 61400-4 standard of wind turbine gearbox design is currently being revised by a joint working group (JWG) of experts in IEC TC 88 (wind energy) and International Organization for Standardization (ISO) TC60 (gears) to further that effort. Experts from ISO TC4 (rolling bearings) and ISO TC28 (lubricants) have actively participated. This revision has implemented lessons learned from industry use of edition 1 since its publication in 2012. The main document, IEC 61400-4, was pared down to essential design requirements and application-specific recommendations along with a design verification framework. The JWG leveraged concurrent development of other standards, such as IEC 61400-8 on wind turbine structures, to replace edition 1 content. These are described along with how this works with the IEC Renewable Energy certification scheme for wind turbines (IECRE-WE). The JWG recognized the interest in maintaining informative parts of edition 1 including annexes on wind turbine architecture and loads, bearing and gear arrangements, bearing selection, lubrication system descriptions and lubricant performance recommendations. This information was retained in two technical reports: IEC/TR 61400-4-2 Lubrication and IEC/TR 61400-4-3 Explanatory Notes. Additionally, a technical specification, IEC/TS 61400-4-1, was drafted to provide a reliability calculation method for comparing different design options or conditions. Salient elements of these documents are described. All four documents were recently distributed for IEC/ISO review, ballot, and comment. Publication is expected in 2023.

gearbox↗

DOE OSTI2023

A Revised International Standard for Gearboxes in Wind Turbine Systems: Preprint

ENGINEERING,WIND ENERGY↗

DOE OSTI2023

Neutronic engine

An internal combustion engine for neutron diffraction analysis is provided. The engine includes an elongated piston chamber formed from an aluminum alloy to ensure maximum neutron visibility into the combustion chamber. An elongated piston assembly reciprocates within the elongated piston chamber, the piston assembly including an upper piston joined to a lower piston. The upper piston and the lower piston are hollow, thereby reducing the reciprocating mass and increasing neutron access to the combustion chamber. The upper piston is lubricated with a neutron-transparent fluorocarbon lubricant such as perfluoropolyether (PFPE), while the lower piston and the crankcase are lubricated with hydrocarbon lubricant. The engine enables 3D and time-resolved measurements of strain, stress, and temperature, as well as phase transformation, texture, and microstructure.

Wissink, Martin L.↗

DOE OSTI2024

Enhancing the Range and Reliability of the Spacer Layer Imaging Method

The spacer layer imaging method (SLIM) is widely used to measure the thickness of additive and lubricant films, in lubricant development and evaluation, and for fundamental research into elastohydrodynamic lubrication and tribofilm formation mechanisms. The film thickness measurement, as implemented on several popular tribometers, provides powerful, non-destructive in-situ mapping of film topography with nanometre-scale height sensitivity. However, the results can be highly sensitive to experimental procedure, machine condition, and image analysis, in some cases reporting unphysical film thickness trends. The prevailing image analysis techniques make it challenging to interrogate these errors, often hiding their multivariate nonlinear behaviour from the user by spatial averaging. Herein, several common ‘silent errors’ in the SLIM measurement, including colour matching to incorrect fringe orders, and colour drift due to the optical properties of the system or film itself, are discussed, with examples. A robust suite of novel a priori and a posteriori methods to address these issues, and to improve the accuracy and reliability of the measurement, are also presented, including a novel, computationally inexpensive circle-finding algorithm for automated image processing. In combination, these methods allow reliable mapping of films up to at least 800 nm in thickness, representing a significant milestone for the utility of SLIM applied to elastohydrodynamic contact.

EHL film geometry↗

DOE OSTI2022

Macroscale superlubricity by a sacrificial carbon nanotube coating

Superlubricity, i.e., coefficient of friction (COF) below 0.01, was earlier limited to microscale in controlled environments in the earlier literature and more recently realized for macroscale sliding of ceramic or carbon surfaces lubricated by water or other polar fluids. However, there is lack of report of superlubricity for the most common bearing system, i.e., steel-steel contact in non-polar oil lubrication. Here, in this work, we present ultra-low COF of 0.001–0.007 by using a sacrificial coating composed of vertically-aligned carbon nanotubes (CNTs) for macroscale steel-steel sliding under minimum quantity lubrication (MQL) of a polyalphaolefin (PAO) oil in the ambient environment. Raman spectroscopy and electron microscopy analyses detected graphene-containing tribofilms on both the steel surfaces, which was produced by the fractured CNT flakes and metallic wear debris during running-in. The in situ formed graphene-graphene contact interface presumably possesses a low shear resistance leading to superlubricity. The presence of oil, despite as little as one droplet, has proven to be crucial. Such a superlubricity performance has shown good sustainability in extended testing of more than 500,000 cycles and strong ability of accommodating changes in sliding conditions. Results here demonstrate feasibility with fundamental insights for achieving ambient environment macroscale superlubricity.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Lignin monomer conversion into biolubricant base oils

Despite progress in the depolymerization of lignin, only a few studies convert the obtained monomers to value-added products. Here we introduce a strategy to synthesize branched benzene lubricant (BBL) and branched cyclic lubricant (BCL) base oils from lignin-derived monomers and aldehyde. We perform carbon–carbon coupling via Brønsted acid-catalyzed hydroxyalkylation/alkylation (HAA) then hydrodeoxygenation (HDO). Optimum HAA reaction conditions achieve up to 90% guaiacol conversion and an HAA product containing 76% BBL and 24% enal condensation product over a P-SiO 2 catalyst. Subsequent HDO of HAA products over an Ir-ReO x /SiO 2 catalyst produces a lubricant-ranged mixture of BCL (C 24 ) up to yield (82%) and small fractions of dodecyl cyclohexane and C 10 and C 15 carbons alkanes. The kinematic viscosity, viscosity index, and Noack volatility of these base oils are comparable to commercial petroleum-derived poly α-olefin Group IV and refrigerant base oils. In conclusion, this approach provides a sustainable pathway for replacing petroleum-derived base oils.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2020

Integrated friction reduction technology to improve fuel economy without sacrificing durability

This project aims to develop fuel economy technologies to minimize parasitic losses within vehicle engines and drivetrains by improving fuel economy at least 2% for 2014 legacy vehicles and 2018 vehicles without adverse impacts on engine durability. The tools used are advanced low viscosity lubricants and surface material technologies, including surface textures, and coatings. Working with industrial partners, an experimental fuel efficient low viscosity lubricant was developed, verified by ASTM fuel economy engine test for 2014 vehicle population. An ultralow viscosity lubricant was also developed for 2018 engines, demonstrated by engine chassis dynamometer tests. Surface texturing of engine components was also conducted, and in engine testing, confirmed the textured engine developed more torque and power while the textures largely stayed intact after the test.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗