Engineering topics

Bruckner, Robert J.

Publications and source records attributed to Bruckner, Robert J..

At least 19 records

NASA NTRS2018

High Speed Bearing Wear Rate Measurements for Spacecraft Active Thermal Control Fluid Pumps with a Novel Pin on Disk Apparatus

A novel pin on disc tribometer was designed and constructed to generate a high-speed, wear coefficient database for hydrodynamic bearings that are typically used in canned motors found in the active thermal control circuits of robotic and inhabited spacecraft. The primary motivation for this work was the premature failure of the active external thermal control pump on the International Space Station in 2010. During the failure investigation of this incident, the root cause was postulated to be high speed wear of the bearings. Although a detailed forensic analysis gave credibility to this theory, the lack of wear coefficient data at relevant conditions prevented validation of this finding. The database generated from the new Extreme Environment Tribometer (EET) enabled a closure calculation within 5% of the observed wear from inspections of the failed hardware. Testing in anhydrous ammonia and surrogate fluid was performed to provide a means for simplified testing in the future and to populate a preliminary database for the design of future active thermal control systems on spacecraft. The EET and test techniques developed for the measurement of high-speed wear coefficients are available to future system designers.

thermal control↗

NASA NTRS2015

Passive Thermal Management of Foil Bearings

Systems and methods for passive thermal management of foil bearing systems are disclosed herein. The flow of the hydrodynamic film across the surface of bearing compliant foils may be disrupted to provide passive cooling and to improve the performance and reliability of the foil bearing system.

Bruckner, Robert J.↗

NASA NTRS2014

ISS Ammonia Pump Failure, Recovery, and Lesson Learned A Hydrodynamic Bearing Perspective

The design, development, and operation of long duration spaceflight hardware has become an evolutionary process in which meticulous attention to details and lessons learned from previous experiences play a critical role. Invaluable to this process is the ability to retrieve and examine spaceflight hardware that has experienced a premature failure. While these situations are rare and unfortunate, the failure investigation and recovery from the event serve a valuable purpose in advancing future space mechanism development. Such a scenario began on July 31, 2010 with the premature failure of an ammonia pump on the external active thermal control system of the International Space Station. The ground-based inspections of the returned pump and ensuing failure investigation revealed five potential bearing forces that were un-accounted for in the design phase and qualification testing of the pump. These forces could combine in a number of random orientations to overload the pump bearings leading to solid-surface contact, wear, and premature failure. The recovery plan identified one of these five forces as being related to the square of the operating speed of the pump and this fact was used to recover design life through a change in flight rules for the operation of the pump module. Through the course of the failure investigation, recovery, and follow-on assessment of pump wear life, design guidance has been developed to improve the life of future mechanically pumped thermal control systems for both human and robotic exploration missions.

Bruckner, Robert J.↗

NASA NTRS2012

Performance of Simple Gas Foil Thrust Bearings in Air

Foil bearings are self-acting hydrodynamics devices used to support high speed rotating machinery. The advantages that they offer to process fluid lubricated machines include: high rotational speed capability, no auxiliary lubrication system, non-contacting high speed operation, and improved damping as compared to rigid hydrodynamic bearings. NASA has had a sporadic research program in this technology for almost 6 decades. Advances in the technology and understanding of foil journal bearings have enabled several new commercial products in recent years. These products include oil-free turbochargers for both heavy trucks and automobiles, high speed electric motors, microturbines for distributed power generation, and turbojet engines. However, the foil thrust bearing has not received a complimentary level of research and therefore has become the weak link of oil-free turbomachinery. In an effort to both provide machine designers with basic performance parameters and to elucidate the underlying physics of foil thrust bearings, NASA Glenn Research Center has completed an effort to experimentally measure the performance of simple gas foil thrust bearing in air. The database includes simple bump foil supported thrust bearings with full geometry and manufacturing techniques available to the user. Test conditions consist of air at ambient pressure and temperatures up to 500 C and rotational speeds to 55,000 rpm. A complete set of axial load, frictional torque, and rotational speed is presented for two different compliant sub-structures and inter-pad gaps. Data obtained from commercially available foil thrust bearings both with and without active cooling is presented for comparison. A significant observation made possible by this data set is the speed-load capacity characteristic of foil thrust bearings. Whereas for the foil journal bearing the load capacity increases linearly with rotational speed, the foil thrust bearing operates in the hydrodynamic high speed limit. In this case, the load capacity is constant and in fact often decreases with speed if other factors such as thermal conditions and runner distortions are permitted to dominate the bearing performance.

Bruckner, Robert J.↗

NASA NTRS2010

Integration Methodology For Oil-Free Shaft Support Systems: Four Steps to Success

Commercial applications for Oil-Free turbomachinery are slowly becoming a reality. Micro-turbine generators, highspeed electric motors, and electrically driven centrifugal blowers are a few examples of products available in today's commercial marketplace. Gas foil bearing technology makes most of these applications possible. A significant volume of component level research has led to recent acceptance of gas foil bearings in several specialized applications, including those mentioned above. Component tests identifying such characteristics as load carrying capacity, power loss, thermal behavior, rotordynamic coefficients, etc. all help the engineer design foil bearing machines, but the development process can be just as important. As the technology gains momentum and acceptance in a wider array of machinery, the complexity and variety of applications will grow beyond the current class of machines. Following a robust integration methodology will help improve the probability of successful development of future Oil-Free turbomachinery. This paper describes a previously successful four-step integration methodology used in the development of several Oil-Free turbomachines. Proper application of the methods put forward here enable successful design of Oil-Free turbomachinery. In addition when significant design changes or unique machinery are developed, this four-step process must be considered.

Howard, Samuel A.↗

NASA NTRS2010

Remaining Technical Challenges and Future Plans for Oil-Free Turbomachinery

The application of Oil-Free technologies (foil gas bearings, solid lubricants and advanced analysis and predictive modeling tools) to advanced turbomachinery has been underway for several decades. During that time, full commercialization has occurred in aircraft air cycle machines, turbocompressors and cryocoolers and ever-larger microturbines. Emerging products in the automotive sector (turbochargers and superchargers) indicate that high volume serial production of foil bearings is imminent. Demonstration of foil bearings in APU s and select locations in propulsion gas turbines illustrates that such technology also has a place in these future systems. Foil bearing designs, predictive tools and advanced solid lubricants have been reported that can satisfy anticipated requirements but a major question remains regarding the scalability of foil bearings to ever larger sizes to support heavier rotors. In this paper, the technological history, primary physics, engineering practicalities and existing experimental and experiential database for scaling foil bearings are reviewed and the major remaining technical challenges are identified.

DellaCorte, Christopher↗

NASA NTRS2010

An Assessment of Gas Foil Bearing Scalability and the Potential Benefits to Civilian Turbofan Engines

Over the past several years the term oil-free turbomachinery has been used to describe a rotor support system for high speed turbomachinery that does not require oil for lubrication, damping, or cooling. The foundation technology for oil-free turbomachinery is the compliant foil bearing. This technology can replace the conventional rolling element bearings found in current engines. Two major benefits are realized with this technology. The primary benefit is the elimination of the oil lubrication system, accessory gearbox, tower shaft, and one turbine frame. These components account for 8 to 13 percent of the turbofan engine weight. The second benefit that compliant foil bearings offer to turbofan engines is the capability to operate at higher rotational speeds and shaft diameters. While traditional rolling element bearings have diminished life, reliability, and load capacity with increasing speeds, the foil bearing has a load capacity proportional to speed. The traditional applications for foil bearings have been in small, lightweight machines. However, recent advancements in the design and manufacturing of foil bearings have increased their potential size. An analysis, grounded in experimentally proven operation, is performed to assess the scalability of the modern foil bearing. This analysis was coupled to the requirements of civilian turbofan engines. The application of the foil bearing to larger, high bypass ratio engines nominally at the 120 kN (approx.25000 lb) thrust class has been examined. The application of this advanced technology to this system was found to reduce mission fuel burn by 3.05 percent.

Bruckner, Robert J.↗

NASA NTRS2010

Advancements Toward Oil-Free Rotorcraft Propulsion

NASA and the Army have been working for over a decade to advance the state-of-the-art (SOA) in Oil-Free Turbomachinery with an eye toward reduced emissions and maintenance, and increased performance and efficiency among other benefits. Oil-Free Turbomachinery is enabled by oil-free gas foil bearing technology and relatively new high-temperature tribological coatings. Rotorcraft propulsion is a likely candidate to apply oil-free bearing technology because the engine size class matches current SOA for foil bearings and because foil bearings offer the opportunity for higher speeds and temperatures and lower weight, all critical issues for rotorcraft engines. This paper describes an effort to demonstrate gas foil journal bearing use in the hot section of a full-scale helicopter engine core. A production engine hot-core location is selected as the candidate foil bearing application. Rotordynamic feasibility, bearing sizing, and load capability are assessed. The results of the program will help guide future analysis and design in this area by documenting the steps required and the process utilized for successful application of oil-free technology to a full-scale engine.

Howard, Samuel A.↗

NASA NTRS2009

Windage Power Loss in Gas Foil Bearings and the Rotor-Stator Clearance of High Speed Generators Operating in High Pressure Environments

Closed Brayton Cycle (CBC) and Closed Supercritical Cycle (CSC) engines are prime candidates to convert heat from a reactor into electric power for robotic space exploration and habitation. These engine concepts incorporate a permanent magnet starter/generator mounted on the engine shaft along with the requisite turbomachinery. Successful completion of the long-duration missions currently anticipated for these engines will require designs that adequately address all losses within the machine. The preliminary thermal management concept for these engine types is to use the cycle working fluid to provide the required cooling. In addition to providing cooling, the working fluid will also serve as the bearing lubricant. Additional requirements, due to the unique application of these microturbines, are zero contamination of the working fluid and entirely maintenance-free operation for many years. Losses in the gas foil bearings and within the rotor-stator gap of the generator become increasingly important as both rotational speed and mean operating pressure are increased. This paper presents the results of an experimental study, which obtained direct torque measurements on gas foil bearings and generator rotor-stator gaps. Test conditions for these measurements included rotational speeds up to 42,000 revolutions per minute, pressures up to 45 atmospheres, and test gases of nitrogen, helium, and carbon dioxide. These conditions provided a maximum test Taylor number of nearly one million. The results show an exponential rise in power loss as mean operating density is increased for both the gas foil bearing and generator windage. These typical "secondary" losses can become larger than the total system output power if conventional design paradigms are followed. A nondimensional analysis is presented to extend the experimental results into the CSC range for the generator windage.

Bruckner, Robert J.↗

NASA NTRS2008

Compliant Foil Journal Bearing Performance at Alternate Pressures and Temperatures

An experimental test program has been conducted to determine the highly loaded performance of current generation gas foil bearings at alternate pressures and temperatures. Typically foil bearing performance has been reported at temperatures relevant to turbomachinery applications but only at an ambient pressure of one atmosphere. This dearth of data at alternate pressures has motivated the current test program. Two facilities were used in the test program, the ambient pressure rig and the high pressure rig. The test program utilized a 35 mm diameter by 27 mm long foil journal bearing having an uncoated Inconel X-750 top foil running against a shaft with a PS304 coated journal. Load capacity tests were conducted at 3, 6, 9, 12, 15, 18, and 21 krpm at temperatures from 25 to 500 C and at pressures from 0.1 to 2.5 atmospheres. Results show an increase in load capacity with increased ambient pressure and a reduction in load capacity with increased ambient temperature. Below one-half atmosphere of ambient pressure a dramatic loss of load capacity is experienced. Additional lightly loaded foil bearing performance in nitrogen at 25 C and up to 48 atmospheres of ambient pressure has also been reported. In the lightly loaded region of operation the power loss increases for increasing pressure at a fixed load. Knowledge of foil bearing performance at operating conditions found within potential machine applications will reduce program development risk of future foil bearing supported turbomachines.

Bruckner, Robert J.↗

NASA NTRS2008

Compliant Foil Journal Bearing Performance at Alternate Pressures and Temperatures

Bruckner, Robert J.↗

NASA NTRS2008

Preliminary Analysis for an Optimized Oil-Free Rotorcraft Engine Concept

Recent developments in gas foil bearing technology have led to numerous advanced high-speed rotating system concepts, many of which have become either commercial products or experimental test articles. Examples include Oil-Free microturbines, motors, generators and turbochargers. The driving forces for integrating gas foil bearings into these high-speed systems are the benefits promised by removing the oil lubrication system. Elimination of the oil system leads to reduced emissions, increased reliability, and decreased maintenance costs. Another benefit is reduced power plant weight. For rotorcraft applications, this would be a major advantage, as every pound removed from the propulsion system results in a payload benefit. Implementing foil gas bearings throughout a rotorcraft gas turbine engine is an important long-term goal that requires overcoming numerous technological hurdles. Adequate thrust bearing load capacity and potentially large gearbox applied radial loads are among them. However, by replacing the turbine end, or hot section, rolling element bearing with a gas foil bearing many of the above benefits can be realized. To this end, engine manufacturers are beginning to explore the possibilities of hot section gas foil bearings in propulsion engines. This paper presents a logical follow-on activity by analyzing a conceptual rotorcraft engine to determine the feasibility of a foil bearing supported core. Using a combination of rotordynamic analyses and a load capacity model, it is shown to be reasonable to consider a gas foil bearing core section.

Howard, Samuel A.↗

NASA NTRS2007

System Analysis and Performance Benefits of an Optimized Rotorcraft Propulsion System

The propulsion system of rotorcraft vehicles is the most critical system to the vehicle in terms of safety and performance. The propulsion system must provide both vertical lift and forward flight propulsion during the entire mission. Whereas propulsion is a critical element for all flight vehicles, it is particularly critical for rotorcraft due to their limited safe, un-powered landing capability. This unparalleled reliability requirement has led rotorcraft power plants down a certain evolutionary path in which the system looks and performs quite similarly to those of the 1960 s. By and large the advancements in rotorcraft propulsion have come in terms of safety and reliability and not in terms of performance. The concept of the optimized propulsion system is a means by which both reliability and performance can be improved for rotorcraft vehicles. The optimized rotorcraft propulsion system which couples an oil-free turboshaft engine to a highly loaded gearbox that provides axial load support for the power turbine can be designed with current laboratory proven technology. Such a system can provide up to 60% weight reduction of the propulsion system of rotorcraft vehicles. Several technical challenges are apparent at the conceptual design level and should be addressed with current research.

Bruckner, Robert J.↗

NASA NTRS2007

Oil-Free Rotor Support Technologies for an Optimized Helicopter Propulsion System

An optimized rotorcraft propulsion system incorporating a foil air bearing supported Oil-Free engine coupled to a high power density gearbox using high viscosity gear oil is explored. Foil air bearings have adequate load capacity and temperature capability for the highspeed gas generator shaft of a rotorcraft engine. Managing the axial loads of the power turbine shaft (low speed spool) will likely require thrust load support from the gearbox through a suitable coupling or other design. Employing specially formulated, high viscosity gear oil for the transmission can yield significant improvements (approx. 2X) in allowable gear loading. Though a completely new propulsion system design is needed to implement such a system, improved performance is possible.

DellaCorte, Christopher↗

NASA NTRS2007

Design, Fabrication and Performance of Open Source Generation I and II Compliant Hydrodynamic Gas Foil Bearings

Foil gas bearings are self-acting hydrodynamic bearings made from sheet metal foils comprised of at least two layers. The innermost top foil layer traps a gas pressure film that supports a load while a layer or layers underneath provide an elastic foundation. Foil bearings are used in many lightly loaded, high-speed turbo-machines such as compressors used for aircraft pressurization, and small micro-turbines. Foil gas bearings provide a means to eliminate the oil system leading to reduced weight and enhanced temperature capability. The general lack of familiarity of the foil bearing design and manufacturing process has hindered their widespread dissemination. This paper reviews the publicly available literature to demonstrate the design, fabrication and performance testing of both first and second generation bump style foil bearings. It is anticipated that this paper may serve as an effective starting point for new development activities employing foil bearing technology.

DellaCorte, Christopher↗

NASA NTRS2007

Gas Foil Bearing Technology Advancements for Closed Brayton Cycle Turbines

Closed Brayton Cycle (CBC) turbine systems are under consideration for future space electric power generation. CBC turbines convert thermal energy from a nuclear reactor, or other heat source, to electrical power using a closed-loop cycle. The operating fluid in the closed-loop is commonly a high pressure inert gas mixture that cannot tolerate contamination. One source of potential contamination in a system such as this is the lubricant used in the turbomachine bearings. Gas Foil Bearings (GFB) represent a bearing technology that eliminates the possibility of contamination by using the working fluid as the lubricant. Thus, foil bearings are well suited to application in space power CBC turbine systems. NASA Glenn Research Center is actively researching GFB technology for use in these CBC power turbines. A power loss model has been developed, and the effects of a very high ambient pressure, start-up torque, and misalignment, have been observed and are reported here.

Howard, Samuel A.↗

NASA NTRS2006

A Preliminary Foil Gas Bearing Performance Map

Recent breakthrough improvements in foil gas bearing load capacity, high temperature tribological coatings and computer based modeling have enabled the development of increasingly larger and more advanced Oil-Free Turbomachinery systems. Successful integration of foil gas bearings into turbomachinery requires a step wise approach that includes conceptual design and feasibility studies, bearing testing, and rotor testing prior to full scale system level demonstrations. Unfortunately, the current level of understanding of foil gas bearings and especially their tribological behavior is often insufficient to avoid developmental problems thereby hampering commercialization of new applications. In this paper, a new approach loosely based upon accepted hydrodynamic theory, is developed which results in a "Foil Gas Bearing Performance Map" to guide the integration process. This performance map, which resembles a Stribeck curve for bearing friction, is useful in describing bearing operating regimes, performance safety margins, the effects of load on performance and limiting factors for foil gas bearings.

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.↗