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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS2004

Modification of Bushing Test Rig and Research of Variable Inlet Guide Vane Bushings For Further Development of PM304 Bushings

PS304 is a high temperature solid lubricant coating comprised of a nickel-chrome binder, chrome oxide hardener, barium-calcium fluoride high temperature lubricant, and silver as the low temperature lubricant. This coating is used to lubricate Oil-Free Foil Air Bearings as they experience friction and wear during start up and shut down. The coating deposition process begins with undercutting the shaft. This area is then sandblasted to provide a rough surface for the coating to adhere to. The coating powder is then sent through the plasma spray gun and a reasonably thick layer is applied to the undercut area of the shaft. The coating is then ground down even with the surface of the shaft and gets a nice polished finish. The foil air bearings use the solid lubricant, as mentioned above, during start up and shut down. During normal operating conditions, generally above 2000RPM, the bearings utilize air as their lubricant. Foil air bearings are comprised of a thin top foil and a corrugated bump foil. They have an interference fit with the shaft before operation. As the air gets "trapped" between the top foil and the shaft, it presses the top foil against the bump foil, in turn compressing the bumps. As the bumps compress, it allows for the air to separate the top foil from the shaft, therefore, utilizing the trapped air as its lubricant.

Yanke, Anne↗
DOE OSTI2024

2024.03.13 Bushing Subcommittee presentation on Transformer Bushing Seismic Resilience: Design, Hazard, & Prevention Analysis [Slides]

Presents results from power grid simulations on synthetic grids that estimate the impact from power transformer failures due to earthquakes. In the best-case scenario, there is an 82.9% likelihood of load loss greater or equal to 51 MW. Methodologies are described as well as path forward to improving transformer resilience and, consequently, the resilience of the bulk power grid.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2025

Self-Lubricating Bushing Testing for John Day Dam Ka plan Turbine Replacement

The goal of this testing program is to find suitable self-lubricated alternatives to replace the in use oil lubricated grooved-bronze bushing in Kaplan runner hubs that are currently being utilized at John Day Dam operated by the U.S. Army Corps of Engineers (USACE). Scaled bushing testing utilizing a Pacific Northwest National Laboratory designed, fabricated, and operated Bushing Test Stand under the direction and funding from USACE determined that self-lubricated bushings tested appear capable of outperforming the current oil-lubricated bronze bushings. Performance tests are focused on durability which includes cyclic load bearing properties and articulations under various loading scenarios. This testing was performed at nominally 1/5 th scale. A scaling sensitivity analysis determined that scaled testing results apply to prototypic size. This report shows the direct comparison between the current baseline bronze bushing to self-lubricated bushings from various manufacturers. Bushing data like coefficient of friction and bushing material loss (associated with bushing wear) was determined. Self-lubricated bushings tested include products manufactured specifically for hydropower applications by the following companies: Trelleborg, Kamatics, Anonymous, and Tenneco/Deva.

42 ENGINEERING↗
NASA NTRS2004

PS300 Tribomaterials Evaluated at 6500C by Bushing Test Rig

A new facility has been developed to test the tribological behavior (friction and wear) of PS300 solid lubricant bushings at high temperatures. PS300 is a commercially available solid lubricant invented at the NASA Glenn Research Center. It can be prepared as a plasma spray coating or as a free-standing powder metallurgy component, designated PM300. PS300 and PM300 composites are designed to lubricate sliding components at temperatures above the capability of today's best oils, greases, and solid lubricants. One of the primary applications being pursued for PM300 is the development of bushings for use in high-temperature machinery. Examples include inlet guide vane bushings for gas turbines and conveyors, and bearings for industrial furnaces and ovens. Encouraging preliminary field trials indicate that PS300 and PM300 lubricant materials have been commercialized successfully in several industrial applications. However, the lack of laboratory performance data has hindered further commercialization especially for new applications that differ significantly from the established experience base. The purpose of the newly developed bushing test rig will be to determine the performance characteristics of PM300, and other materials, under conditions closely matching intended applications. The data will be used to determine engineering friction and wear rates and to estimate the life expectancy of bushings for new applications. In the new rig, the bushing is loaded against a rotating shaft inside a furnace enclosure (see the preceding photograph). Loads can vary from 5 to 200 N, speeds from 1 to 400 rpm, and temperatures from 25 to 800 C. Furnace temperature, bushing temperature, shaft speed, and torque are monitored during the test, and wear of both the bushing and the shaft is measured after testing is completed. Initially, PM300 bushings will be evaluated and compared with lower temperature, traditional bushing materials like graphite and porous bronze. The baseline PM304 composition is 60 wt% NiCr (a binder), 20 wt% Cr2O3 (a hardener), 10 wt% BaF2/CaF2 (a high-temperature lubricant), and 10 wt% Ag (a low-temperature lubricant). Future research efforts will include determining the effects of load, sliding speed, and temperature on tribological performance and, possibly, tailoring composition for specific applications. We expect that the availability of measured performance data will enhance the market penetration of PM300 technology.

Striebing, Donald R.↗
NASA NTRS1998

Low-Cost Production of Composite Bushings for Jet Engine Applications

The objectives of this research program were to reduce the manufacturing costs of variable stator vane bushings by 1) eliminating the expensive carbon fiber braiding operation, 2) replacing the batch mode impregnation, B-stage, and cutting operations with a continuous process, and 3) reducing the molding cycle and machining operations with injection molding to achieve near-net shapes. Braided bushings were successfully fabricated with both AMB-17XLD and AMB-TPD resin systems. The composite bushings achieved high glass transition temperature after post-cure (+300 C) and comparable weight loss to the PNM-15 bushings. ANM-17XLD bushings made with "batch-mode" molding compound (at 0.5 in. fiber length) achieved a +300 lb-force flange break strength which was superior to the continuous braided-fiber reinforced bushing. The non-MDA resin technology developed in this contract appears attractive for bushing applications that do not exceed a 300 C use temperature. Two thermoplastic polyimide resins were synthesized in order to generate injection molding compound powders. Excellent processing results were obtained at injection temperatures in excess of 300 C. Micro-tensile specimens were produced from each resin type and the Tg measurements (by TMA) for these samples were equivalent to AURUM(R). Thermal Gravimetric Analysis (TGA) conducted at 10 C/min showed that the non-MDA AMB-type polyimide thermoplastics had comparable weight loss to PMR-15 up to 500 C.

Gray, Robert A.↗
NASA NTRS1983

Tool for Replacing Bushings

Centerlines of original bushings maintained. Tool frame extends around structure that holds bushings to be removed. Floating bushings of tool positioned with jig pin that slides snugly in old bushing and floating tool bushings. Floating bushings then clamped to tool frame.

Bird, R. G.↗
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↗
DOE OSTI2012

Cryogenic lifetime tests on a commercial epoxy resin high voltage bushing

High-temperature superconducting (HTS) power devices operating in liquid nitrogen frequently require high-voltage bushings to carry the current leads from the superconducting windings to the room temperature grid connections. Oak Ridge National Laboratory is collaborating with Waukesha Electric Systems, SuperPower, and Southern California Edison to develop and demonstrate an HTS utility power transformer. Previous dielectric high voltage tests in support of this program have been carried out in test cryostats with commercial epoxy resin bushings from Electro Composites Inc. (ECI). Though the bushings performed well in these short-term tests, their long-term operation at high voltage in liquid nitrogen needs to be verified for use on the utility grid. Long-term tests are being carried out on a sample 28-kV-class ECI bushing. The bushing has a monolithic cast, cycloaliphatic resin body and is fire- and shatter-resistant. The test cryostat is located in an interlocked cage and is energized at 25 kVac around the clock. Liquid nitrogen (LN) is automatically refilled every 9.5 hours. Partial discharge, capacitance, and leakage resistance tests are periodically performed to check for deviations from factory values. At present, over 2400 hours have been accumulated with no changes in these parameters. The tests are scheduled to run for four to six months.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
NASA NTRS1984

Evaluation of two polyimides and of an improved liner retention design for self-lubricating bushings

Two different polyimide polymers were studied and the effectiveness of a design feature to improve retention of the self lubricating composite liners under high load was evaluated. The basic bearing design consisted of a molded layer of chopped graphite-fiber-reinforced-polyimide (GFRP) composite bonded to the bore of a steel bushing. The friction, wear, and load carrying ability of the bushings were determined in oscillating tests at 25, 260 and 315 C at radial unit loads up to 260 MPa. Friction coefficients were typically 0.15 to 0.25. Bushings with liners containing a new partially fluorinated polymer were functional, but had a lower load capacity and higher wear rate than those containing a more conventional, high temperature polyimide. The liner retention design feature reduced the tendency of the liners to crack and work out of the contact zone under high oscillating loads.

Sliney, H. E.↗
NASA NTRS1995

Vannevar Bush 2: Science for the 21st Century. Why Should Federal Dollars be Spent to Support Scientific Research?

On July 5, 1945, Dr. Vannevar Bush delivered a report to President Truman known as 'Science: The Endless Frontier'. In the report, Dr. Bush stated that 'scientific progress is one essential key to our security as a nation, to our better health, to more jobs, to a higher standard of living, and to our cultural progress'. Bush addressed job creation, the independence of basic research, the ties between research and application, and the nations's need for new talent. In 1995, there are strong similarities between the issues addressed in the Congress, Administration, and the public and those following World War 2. Federal funds and research funding are under severe pressure, including that from fiscal constraints in the federal budget due to the large and growing deficit and the escalating cost of health care. Defense conversion is addressed in the Congress and in industry, where many jobs are at stake. Conversion of the national laboratories, particularly nuclear weapons laboratories, has been a subject of a governmental commission and is the subject of draft legislation. Health care costs and the appropriate role of the federal government in funding basic and applied research has become a major topic of debate. Discussion on education in science has grown from the issue of how to produce more Ph.D.'s to how to improve the understanding of technology and science among the general public.

Miller, Kate↗
NASA NTRS2019

Tribological Performance of PM400 Bushings in Oscillatory Sliding from 25 to 927 °C

Small bore (6.35 millimeter) bushings, made from NASA PM400 solid lubricant composite, were evaluated in oscillatory sliding contact against a nickel-based superalloy shaft. Tests were conducted in air from 25 to 900 degrees Centigrade for extended periods (1 million cycles, plus or minus 15 degrees, 1 hertz) to assess the suitability of PM400 in gas turbine and reciprocating engine exhaust gas path control valve applications. Operating torque and estimated friction was monitored throughout the test duration and wear was measured at the end of test. In general, friction, torque and wear was low. At temperatures above 600 degrees Centigrade, bushing dimensional stability was achieved via short duration pre-test furnace exposure heat treatments. Preliminary test results show that bushings made from NASA PM400 are feasible for aerospace and industrial applications.

high temperature solid lubricants↗
DOE OSTI2016

Heterogeneous WS x /WO 3 thorn-bush nanofiber electrodes for sodium-ion batteries

Heterogeneous electrode materials with hierarchical architectures promise to enable considerable improvement in future energy storage devices. In this study, we report on a tailored synthetic strategy used to create heterogeneous tungsten sulfide/oxide core–shell nanofiber materials with vertically and randomly aligned thorn-bush features, and we evaluate them as potential anode materials for high-performance Na-ion batteries. The WS x (2 ≤ x ≤ 3, amorphous WS 3 and crystalline WS 2 ) nanofiber is successfully prepared by electrospinning and subsequent calcination in a reducing atmosphere. To prevent capacity degradation of the WS x anodes originating from sulfur dissolution, a facile post-thermal treatment in air is applied to form an oxide passivation surface. Interestingly, WO 3 thorn bundles are randomly grown on the nanofiber stem, resulting from the surface conversion. We elucidate the evolving morphological and structural features of the nanofibers during post-thermal treatment. The heterogeneous thorn-bush nanofiber electrodes deliver a high second discharge capacity of 791 mAh g –1 and improved cycle performance for 100 cycles compared to the pristine WS x nanofiber. Lastly, we show that this hierarchical design is effective in reducing sulfur dissolution, as shown by cycling analysis with counter Na electrodes.

36 MATERIALS SCIENCE↗
NASA NTRS2007

Tribological Performance of PM300 Solid Lubricant Bushings for High Temperature Applications

PM300 is a high temperature solid lubricant material produced through conventional powder metallurgy processing. PM300 is a combination of metal binder (NiCr), hardener (Cr2O3) and lubricant (Ag and BaF2/CaF2) phases and is in commercial use in high temperature furnace conveyors. In this paper, the tribological characteristics of PM300 are evaluated using a newly developed bushing test rig in which PM300 bushings are loaded against rotating steel shafts at temperatures from 25 to 650 C. The data shows that friction and wear are low to moderate and that the lubrication performance (friction) improves with increasing temperature. Several alternative PM300 compositions are evaluated which do not contain silver and are targeted at aircraft gas turbine applications in which environmental compatibility of silver is a concern. It is expected that the data resulting from this research will further the commercialization of this technology.

Striebing, Donald R.↗
NASA NTRS2008

A Three-Dimensional Analytic Model for the Scattering of a Spherical Bush

Advanced climate models require a more realistic description of canopy radiation with reasonable computational efficiency. This paper develops the mathematics of scattering from a spherical object conceptualized to be a spherical bush to provide a building block that helps to address this need of climate models. It is composed of a homogeneous distribution of individual smaller objects that scatter isotropically. In the limit of small optical depth, incident radiation will scatter isotropically as the sum of that scattered by all the individual scatterers, but at large optical depth the radiation leaving the spherical bush in a given direction is reduced by mutual shadowing of the smaller objects. In the single scattering limit, the scattering phase function and so the albedo are obtained by simple but accurate analytic expressions derived from analytic integration and numerical evaluation. Except in the limit of thin canopies, the scattering and hence albedos are qualitatively and quantitatively different than those derived from 1-D modeling.

Dickinson, Robert E.↗
DOE OSTI2024

Seismic Resilience of Large Power Transformer Bushings & Non-SF6 Industrial Base Scan Review

Large (high voltage) power transformers (LPT), and more specifically, their bushings, are known to be susceptible to seismic failure. With bushing failure, a transformer will have to be replaced, which has a considerable lead time, adding to the power outage duration. Cost-efficient, proven solutions are not currently available to mitigate this risk, which can persist for the more than 30-year life of a particular transformer. This work will focus on developing and demonstrating a hardware solution to address seismic vulnerabilities and reduce outage risks from LPT failure. Sulfur Hexafluoride (SF6) is a specialty gas with excellent electrical insulation properties which has been used extensively in the power industry. This gas is unfortunately also one of the most potent greenhouse gases known to humanity. A 2014 report by the Intergovernmental Panel on Climate Change found that SF6 has a global warming potential (GWP) 23,000 times higher than Carbon Dioxide, and has the highest GWP of all gases assessed (Myhre 2013). SF6 is almost exclusively man-made and is produced for use as an insulator in high voltage electrical equipment. This makes the production and use of SF6 one of the leading sources of anthropogenic climate change. To fully eliminate the environmental impacts of SF6, alternative technology is needed. The ideal replacement would be a technology that can fulfil the same role as SF6, at the same cost or cheaper, but without adverse environmental effects. Currently, no technology fits this description, however several promising technologies have begun to enter the market. An industry scan was performed to assess the state of industry adoption and manufacturing capability for SF6-free alternative technologies for use at the high-voltage level, and the primary barriers to broader adoption.

10 SYNTHETIC FUELS↗
NASA NTRS1972

Low cost anti-galling bushings

Heat shrinkable Teflon tubing is cut to size, slipped onto shaft, heated to shrink tightly to shaft, or machined to final outside diameter size. Shaft bushings fabricated from shrinkable Teflon tubing provide economic close fitting sleeves that prevent galling and contamination in valves.

Spencer, E. O.↗
NASA NTRS1982

Safety Bolt Doubles as a Bushing-Removal Tool

Bushings fitted to close tolerances and limited access can be removed without damage to housing by using bolt with integrated locking dog. Such self-retaining positive - locking bolts are normally used as fasteners in critical joints where accidentally loosened bolt could cause damage or injuries.

Haverkamp, C. E.↗