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Results for “thermomechanical contact”

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NASA NTRS1984

Thermal and thermomechanical effects in dry sliding

Developments in the study of interrelated thermal and mechanical phenomena in sliding systems are reviewed. The topics reviewed include mechanisms of frictional heating and the distribution of heat during sliding friction, the experimental measurement and analysis of surface and near-surface temperatures resulting from frictional heating, thermal deformation around sliding contacts and the changes in contact geometry caused by thermal deformation and thermoelastic instability, and the thermomechanical stress distribution around the frictionally heated and thermally deformed contact spots. The influence of the thermal and thermomechanical contact phenomena on friction and wear, surface melting, softening, chemical deterioration, and thermocracking are discussed. The phenomena have important implications in the design and application of sliding or sliding-rolling mechanical components such as dynamic seals, brakes, clutches, plastic bearings, solid or boundary-lubricated bearings, and gears.

Kennedy, F. E., Jr.↗

NASA NTRS1974

A thermal, thermoelastic, and wear analysis of high-energy disk brakes

A thermomechanical investigation of the sliding contact problem encountered in high-energy disk brakes is described. The analysis includes a modelling, using the finite element method of the thermoelastic instabilities that cause transient changes in contact area to occur on the friction surface. In order to include the effect of wear at the contact surface, a wear criterion is proposed that results in the prediction of wear rates for disk brakes that are quite close to experimentally determined wear rates. The thermal analysis shows that the transient temperature distribution in a disk brake assembly can be determined more accurately by use of this thermomechanical analysis than by a more conventional analysis that assumes constant contact conditions. It also shows that lower, more desirable, temperatures in disk brakes can be attained by increasing the volume, the thermal conductivity, and, especially, the heat capacity of the brake components.

Kennedy, F. E., Jr.↗

NASA NTRS1991

Elasto-plastic coupled temperature-displacement finite element analysis of two-dimensional rolling-sliding contact with a translating heat source

The present paper describes a transient translating elastoplastic thermomechanical finite element model to study two-dimensional frictional rolling contact. Frictional two-dimensional contact is simulated by repeatedly translating a nonuniform thermomechanical distribution across the surface of an elastoplastic half space. The half space is represented by a two-dimensional finite element mesh with appropriate boundaries. Calculations are for an elastic-perfectly plastic material and the selected thermophysical properties are assumed to be temperature independent. The paper presents temperature variations, stress and plastic strain distributions and deformations. Residual tensile stresses are observed. The magnitude and depth of these stresses depends on (1) the temperature gradients and (2) the magnitudes of the normal and tangential tractions.

Rubin, C. A.↗

NASA NTRS1973

A thermal, thermoelastic, and wear simulation of a high-energy sliding contact problem

This paper describes an investigation of the sliding contact problem encountered in high-energy disk brakes. The analysis includes a simulation modeling, using the finite element method, of the thermoelastic instabilities that cause transient changes in contact to occur on the friction surface. In order to include the effect of wear of the concentrated contacts on the friction surface, a wear criterion is proposed that results in prediction of wear rates for disk brakes that are quite close to experimentally determined wear rates. The thermal analysis shows that the transient temperature distribution in a disk brake can be determined more accurately by use of this thermomechanical analysis than by a more conventional analysis that assumes constant contact conditions. It is also shown that lower, more desirable, temperatures in disk brakes can be attained by increasing the volume, the thermal conductivity, and especially, the heat capacity of the brake components.

Kennedy, F. E., Jr.↗

NASA NTRS1979

Physical/chemical modeling for photovoltaic module life prediction

The paper presents a generalized methodology for identification and evaluation of potential degradation and failure of terrestrial photovoltaic encapsulation. Failure progression modeling and an interaction matrix are utilized to complement the conventional approach to failure degradation mode identification. Comparison of the predicted performance based on these models can produce: (1) constraints on system or component design, materials or operating conditions, (2) qualification (predicted satisfactory function), and (3) uncertainty. The approach has been applied to an investigation of an unexpected delamination failure; it is being used to evaluate thermomechanical interactions in photovoltaic modules and to study corrosion of contacts and interconnects.

Moacanin, J.↗

NASA NTRS1980

Thermomechanical phenomena in high speed rubbing

An analytical approach is presented for the modeling of the thermomechanical interactions which occur in high speed sliding situations. These sliding contact problems which are characterized by active and interrelated thermal and mechanical phenomena could be called 'rub energetics' problems. Analytical models were developed to simulate two different rub situations: high energy braking of disk brakes and high speed rubs of gas path seals in turbine engines. The models proved to be particularly useful in predicting the severe temperatures and deformations near hot contact patches on the rubbing surfaces. The size of the hot patches is generally determined by normal load and the properties of the contacting materials. Temperatures at the contact patches can approach the melting point of the materials, especially at high sliding velocities. These high temperatures can lead to large amounts of near-surface deformation and high wear rates. Decreased contact temperatures can result from using materials with increased thermal conductivity and increased heat capacity or choosing mechanical properties (decreased stiffness, yield stress or coefficient of thermal expansion) which give larger hot spot size.

Kennedy, F. E.↗

NASA NTRS1992

Simple, Lightweight, Thermomechanical Coupling

Self-actuating thermal coupling device is light, and transfers heat efficiently. Coupling is thermostatic, making contact as necessary to maintain nearly steady temperature at hot side of interface. Hot pins on hot plate poised near cold pins on cold-plate. As temperature of hot plate rises, shape-memory wire contracts, drawing hot pin against cold pin. When temperature falls below critical level, wire expands, allowing hot pin to pull away. Critical temperature determined by composition of alloy.

Milam, M. Bruce↗

NASA NTRS1985

Development of new materials for turbopump bearings

The life requirement for the angular contact ball bearings in the Space Shuttle Main Engine (SSME) high pressure oxygen turbopump (HPOTP) is 7.5 hours. In actual operation, significantly shorter service life was experienced. The objective is to identify bearing materials and/or materials processing techniques offering signficant potential for extending HPOTP bearing performance life. Interactive thermomechanical analysis of the HPOTP bearing-shaft system was performed with the SHABERTH computer program. Bearing fatigue life, ball-race contact stress, heat generation rate, bulk ring temperatures and circumferential stress in the inner rings were quantified as functions of radial load, thrust load and ball-race contact friction. Criteria established from the output of this analysis are being used for material candidate selection.

Maurer, R. E.↗

NASA NTRS1985

Computer-aided selection of materials for cryogenic turbopump bearings

The life requirement for the angular contact ball bearings in the Space Shuttle Main Engine (SSME) high-pressure-oxygen turbopump (HPOTP) is 7.5 hours. In actual operation, significantly shorter service life has been experienced. The objective of this current program is to identify bearing materials and/or materials processing techniques offering significant potential for extending HPOTP bearing performance life. A thermomechanical analysis of the HPOTP shaft/bearing system was performed with the SHABERTH (SHaft-BEaring-THermal) computer program. Bearing fatigue life, ball-race contact stress, heat generation rate, bulk ring temperatures, and circumferential stress in the inner rings were quantified as functions of radial load, thrust load, and ball-race contact friction. The analysis results were used to formulate criteria that are being used for the selection of special materials for future turbopump bearings.

Maurer, R. E.↗

NASA NTRS2011

Development of an Extreme High Temperature n-type Ohmic Contact to Silicon Carbide

We report on the initial demonstration of a tungsten-nickel (75:25 at. %) ohmic contact to silicon carbide (SiC) that performed for up to fifteen hours of heat treatment in argon at 1000 C. The transfer length method (TLM) test structure was used to evaluate the contacts. Samples showed consistent ohmic behavior with specific contact resistance values averaging 5 x 10-4 -cm2. The development of this contact metallization should allow silicon carbide devices to operate more reliably at the present maximum operating temperature of 600 C while potentially extending operations to 1000 C. Introduction Silicon Carbide (SiC) is widely recognized as one of the materials of choice for high temperature, harsh environment sensors and electronics due to its ability to survive and continue normal operation in such environments [1]. Sensors and electronics in SiC have been developed that are capable of operating at temperatures of 600 oC. However operating these devices at the upper reliability temperature threshold increases the potential for early degradation. Therefore, it is important to raise the reliability temperature ceiling higher, which would assure increased device reliability when operated at nominal temperature. There are also instances that require devices to operate and survive for prolonged periods of time above 600 oC [2, 3]. This is specifically needed in the area of hypersonic flight where robust sensors are needed to monitor vehicle performance at temperature greater than 1000 C, as well as for use in the thermomechanical characterization of high temperature materials (e.g. ceramic matrix composites). While SiC alone can withstand these temperatures, a major challenge is to develop reliable electrical contacts to the device itself in order to facilitate signal extraction

Evans, Laura J.↗

NASA NTRS1983

An experimental investigation and numerical prediction of thermomechanical phenomena in high speed rotor tip rubbing

A thermomechanical study of the intermittent rubbing of a rotor blade tip and a casing seal is carried out taking into account the existence of thermal contact resistance. The effect of the thermal properties of a plasma sprayed coating on the blade tip is studied. The influence of a variable heat generation and variable thermal contact resistance at the blade tip as it passes along the path of rubbing is also discussed.

Emery, A. F.↗

NASA NTRS1988

Computer-aided design analysis of 57-mm, angular-contact, cryogenic turbopump bearings

The Space Shuttle main engine high-pressure oxygen turbopumps have not experienced the sevice life required of them. This insufficiency has been due in part to the shortened life of the bearings. To improve the life of the existing turbopump bearings, an effort is under way to investigate bearing modifications that could be retrofitted into the present bearing cavity. Several bearing parameters were optimized using the computer program SHABERTH, which performs a thermomechanical simulation of a load support system. The computer analysis showed that improved bearing performance is feasible if low friction coefficients can be attained. Bearing geometries were optimized considering heat generation, equilibrium temperatures, and relative life. Thermal gradients through the bearings were found to be lower with liquid lubrication than with solid film lubrication, and a liquid oxygen coolant flowrate of approximately 4.0 kg/s was found to be optimal. This paper describes the analytical modeling used to determine these feasible modifications to improve bearing performance.

Armstrong, Elizabeth S.↗

NASA NTRS1991

Application of powder densification models to the consolidation processing of composites

Unidirectional fiber reinforced metal matrix composite tapes (containing a single layer of parallel fibers) can now be produced by plasma deposition. These tapes can be stacked and subjected to a thermomechanical treatment that results in a fully dense near net shape component. The mechanisms by which this consolidation step occurs are explored, and models to predict the effect of different thermomechanical conditions (during consolidation) upon the kinetics of densification are developed. The approach is based upon a methodology developed by Ashby and others for the simpler problem of HIP of spherical powders. The complex problem is devided into six, much simpler, subproblems, and then their predicted contributions are added to densification. The initial problem decomposition is to treat the two extreme geometries encountered (contact deformation occurring between foils and shrinkage of isolated, internal pores). Deformation of these two geometries is modelled for plastic, power law creep and diffusional flow. The results are reported in the form of a densification map.

Wadley, H. N. G.↗

NASA NTRS1988

Bearing optimization for SSME HPOTP application

The space shuttle main engine (SSME) high-pressure oxygen turbopumps (HPOTP) have not experienced the service life required of them. To improve the life of the existing turbopump bearings, modifications to the bearings that could be retrofitted into the present bearing cavity are being investigated. Several bearing parameters were optimized using the computer program SHABERTH, which performs a thermomechanical simulation of a load support system. The computer analysis showed that improved bearing performance is feasible if low friction coefficients can be attained. Bearing geometries were optimized considering heat generation, equilibrium temperatures, and relative life. Two sets of curvatures were selected from the optimization: an inner-raceway curvature of 0.54, an outer-raceway curvature of 0.52, and an inner-raceway curvature of 0.55, an outer-raceway curvature of 0.53. A contact angle of 16 deg was also selected. Thermal gradients through the bearings were found to be lower with liquid lubrication than with solid film lubrication. As the coolant flowrate through the bearing increased, the ball temperature decreased but at a continuously decreasing rate. The optimum flowrate was approximately 4 kg/s. The analytical modeling used to determine these feasible modifications to improve bearing performance is described.

Armstrong, Elizabeth S.↗

NASA NTRS2004

SiC-Based Miniature High-Temperature Cantilever Anemometer

The figure depicts a miniature cantilever-type anemometer that has been developed as a prototype of compact, relatively nonintrusive anemometers that can function at temperatures up to 600 C and that can be expected to be commercially mass-producible at low cost. The design of this anemometer, and especially the packaging aspect of the design, is intended to enable measurement of turbulence in the high-temperature, high-vibration environment of a turbine engine or in any similar environment. The main structural components of the anemometer include a single-crystal SiC cantilever and two polycrystalline SiC clamping plates, all made from chemical-vapor-deposited silicon carbide. Fabrication of these components from the same basic material eliminates thermal-expansion mismatch, which has introduced spurious thermomechanical stresses in cantilever-type anemometers of prior design. The clamping plates are heavily oxidized to improve electrical insulation at high temperature. A cavity that serves as a receptacle for the clamped end of the cantilever is etched into one end of one clamping plate. Trenches that collectively constitute a socket for a multipin electrical plug (for connection to external electronic circuitry) are etched into the opposite end of this clamping plate. Metal strips for electrical contact are deposited on one face of the other clamping plate. Piezoresistive single-crystal SiC thin-film strain gauges are etched in the n-type SiC epilayer in a Wheatstone-bridge configuration. Metal contact pads on the cantilever that extend into the clamping-receptacle area, are obtained by deposition and patterning using standard semiconductor photolithography and etching methods. The cantilever and the two clamping plates are assembled into a sandwich structure that is then clamped in a stainless-steel housing. The Wheatstone- bridge carrying SiC cantilever with the metal contact pads on the piezoresistors is slid into the receptacle in the bottom clamping plate. The top clamping plate is brought into contact with the bottom plate so that the narrow section of the metal strips on the top clamp plate aligns with the metal contact pads on the cantilever. When the parts are clamped together, the metal strips provide electrical connections between the Wheatstone-bridge contact points and the sides the trenches that constitute the socket for the multipin electrical plug. Hence, to connect the Wheatstone bridge to external circuitry for processing of the anemometer readout, one need only insert the plug in the socket. In operation, the cantilever end of the stainless-steel housing is mounted flush with an engine wall and the unclamped portion of the cantilever is exposed into the flow. The cantilever is deflected in direct proportion to the force induced by component of flow parallel to the engine wall and perpendicular to the broad exposed face of the cantilever. The maximum strain on the cantilever occurs at the clamped edge and is measured by the piezoresistors, which are located there. The corresponding changes in resistance manifest themselves in the output of the Wheatstone bridge.

Okojie, Robert S.↗

NASA NTRS2007

Cryogenic Shrouds for Testing Thermal-Insulation Panels

Cryogenic shrouds have been designed and built for use in thermomechanical testing of samples of thermalinsulation panels on cryogenic vessels. In the original application for which these shrouds were specifically designed, the samples are representative of the large-area thermal-insulation panels on the space-shuttle external tanks that hold liquid hydrogen and liquid oxygen, and the purpose of the testing is to demonstrate the ability of bonded layers in the panels to resist delamination under a combination of applied uniaxial mechanical loads and realistic operational temperatures. Presumably, the shrouds and the tests performed by use of them could be modified to enable similar evaluation of thermomechanical properties of thermal-insulation panels for cryogenic vessels other than the external tanks of the space shuttles. The shrouds are required to enable maintenance of required temperatures on the inner and outer surfaces of the thermal-insulation-panel samples, to enable visual observation of the outer surfaces of the samples, and not to introduce any measurable loads into the panels. For each panel sample, there are two shrouds: one to be mounted on the inner surface (the surface that would be in contact with a tank containing a cryogenic liquid during normal use) and one to be mounted on the outer surface (the surface that would be exposed to ambient air or other warmer environment during normal use). The shrouds for testing specimens of thermal-insulation- panels for the liquid-hydrogen tank are made largely of titanium; the shrouds for testing specimens of thermal- insulation-panels for the liquid-oxygen tank are made largely of an aluminum- lithium alloy. The specific temperature requirements are the following: The inner shroud must make it possible to maintain a temperature of 321 degrees F (196 degrees C) [the approximate temperature of liquid nitrogen] or 453 F (about 269 C) [the approximate temperature of liquid helium] on the inner face of the sample. The outer shroud must make it possible to maintain a temperature between 30 degrees and 0 degrees F (between about 34 degrees and about 18 degrees C) on the outer surface of the sample by blowing a cryogenic gas or missile grade air along that surface. To enable viewing of the outer surface of the sample during testing, the outer shroud includes a window comprising two layers of poly(methyl methacrylate) with a gap between them to reduce fogging. To ensure that the shrouds do not introduce any measurable loads into a panel specimen, the shrouds are cushioned on the specimen by seals made of a fluoropolymer-membrane/fabric composite material and are held in place on the specimen by means of symmetrically placed clamps with poly(tetrafluoroethylene) pads. Instrumentation ports for thermocouples and strain gauges used in the tests are incorporated into the shrouds.

Norris, Jeffrey↗

NASA NTRSDate not supplied

Thermomechanical Modeling of Woven Materials With Particle-Based, Explicit-Fiber Simulations

Fiber-based materials are extensively used to protect spacecraft during entry. Insulative fibers, often in a fiber network or woven, provide rigidity, strength, and control of material anisotropy and density. Woven thermal protection materials, such as ADEPT (Adaptable, Deployable Entry and Placement Technology), 3D-MAT (3-Dimensional Multifunctional Ablative Thermal Protection), and 3MDCP (3D Woven Mid-Density Carbon Phenolic), enable missions with stronger and denser materials for entry profiles with high shear and heat flux. Vulnerabilities to woven thermal protection materials include manufacturing-induced material property variation, and impact from micrometeoroids. Simulating woven materials under these conditions require models that can resolve hierarchal structures, thermomechanical behavior, and failure. To address this, we simulate weave thermal conduction and mechanical deformation. We simulate the full weave with a coarse-grained yarn model is presented. The model combines a validated, high-resolution single 3MDCP yarn model and phenolic resin model. Instead of modeling every fiber, each yarn ply with order 10, instead of order 1000, fibers. The discrete element bonded particle model (DEM-BPM) of fibers captures the thermal and mechanical behavior within and between fibers. We study the proportion of heat transfer and stress via the contact network, fiber bonds, and overall weave geometry.

bonded particle↗

NASA NTRS2000

Fretting Stresses in Single Crystal Superalloy Turbine Blade Attachments

Single crystal nickel base superalloy turbine blades are being utilized in rocket engine turbopumps and turbine engines because of their superior creep, stress rupture, melt resistance and thermomechanical fatigue capabilities over polycrystalline alloys. Currently the most widely used single crystal nickel base turbine blade superalloys are PWA 1480/1493 and PWA 1484. These alloys play an important role in commercial, military and space propulsion systems. High Cycle Fatigue (HCF) induced failures in aircraft gas turbine and rocket engine turbopump blades is a pervasive problem. Blade attachment regions are prone to fretting fatigue failures. Single crystal nickel base superalloy turbine blades are especially prone to fretting damage because the subsurface shear stresses induced by fretting action at the attachment regions can result in crystallographic initiation and crack growth along octahedral planes. Furthermore, crystallographic crack growth on octahedral planes under fretting induced mixed mode loading can be an order of magnitude faster than under pure mode I loading. This paper presents contact stress evaluation in the attachment region for single crystal turbine blades used in the NASA alternate Advanced High Pressure Fuel Turbo Pump (HPFTP/AT) for the Space Shuttle Main Engine (SSME). Single crystal materials have highly orthotropic properties making the position of the crystal lattice relative to the part geometry a significant factor in the overall analysis. Blades and the attachment region are modeled using a large-scale 3D finite element (FE) model capable of accounting for contact friction, material orthotrophy, and variation in primary and secondary crystal orientation. Contact stress analysis in the blade attachment regions is presented as a function of coefficient of friction and primary and secondary crystal orientation, Stress results are used to discuss fretting fatigue failure analysis of SSME blades. Attachment stresses are seen to reach peak values at locations where fretting cracks have been observed. Fretting stresses at the attachment region are seen to vary significantly as a function of crystal orientation. Attempts to adapt techniques used for estimating fatigue life in the airfoil region, for life calculations in the attachment region, are presented. An effective model for predicting crystallographic crack initiation under mixed mode loading is required for life prediction under fretting action.

Arakere, Nagaraj K.↗