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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 199 records · Page 11
All sourcesNASA NTRSDOE OSTI
NASA NTRS2005

The Influence of Roughness on Gear Surface Fatigue

Gear working surfaces are subjected to repeated rolling and sliding contacts, and often designs require loads sufficient to cause eventual fatigue of the surface. This research provides experimental data and analytical tools to further the understanding of the causal relationship of gear surface roughness to surface fatigue. The research included evaluations and developments of statistical tools for gear fatigue data, experimental evaluation of the surface fatigue lives of superfinished gears with a near-mirror quality, and evaluations of the experiments by analytical methods and surface inspections. Alternative statistical methods were evaluated using Monte Carlo studies leading to a final recommendation to describe gear fatigue data using a Weibull distribution, maximum likelihood estimates of shape and scale parameters, and a presumed zero-valued location parameter. A new method was developed for comparing two datasets by extending the current methods of likelihood-ratio based statistics. The surface fatigue lives of superfinished gears were evaluated by carefully controlled experiments, and it is shown conclusively that superfinishing of gears can provide for significantly greater lives relative to ground gears. The measured life improvement was approximately a factor of five. To assist with application of this finding to products, the experimental condition was evaluated. The fatigue life results were expressed in terms of specific film thickness and shown to be consistent with bearing data. Elastohydrodynamic and stress analyses were completed to relate the stress condition to fatigue. Smooth-surface models do not adequately explain the improved fatigue lives. Based on analyses using a rough surface model, it is concluded that the improved fatigue lives of superfinished gears is due to a reduced rate of near-surface micropitting fatigue processes, not due to any reduced rate of spalling (sub-surface) fatigue processes. To complete the evaluations, surface inspection were completed. The surface topographies of the ground gears changed substantially due to running, but the topographies of the superfinished gears were essentially unchanged with running.

Krantz, Timothy↗
NASA NTRS2008

High Velocity Linear Induction Launcher with Exit-Edge Compensation for Testing of Aerospace Components

Advances in ultra high speed linear induction electromagnetic launchers over the past decade have focused on magnetic compensation of the exit and entry-edge transient flux wave to produce efficient and compact linear electric machinery. The paper discusses two approaches to edge compensation in long-stator induction catapults with typical end speeds of 150 to 1,500 m/s. In classical linear induction machines, the exit-edge effect is manifest as two auxiliary traveling waves that produce a magnetic drag on the projectile and a loss of magnetic flux over the main surface of the machine. In the new design for the Stator Compensated Induction Machine (SCIM) high velocity launcher, the exit-edge effect is nulled by a dual wavelength machine or alternately the airgap flux is peaked at a location prior to the exit edge. A four (4) stage LIM catapult is presently being constructed for 180 m/s end speed operation using double-sided longitudinal flux machines. Advanced exit and entry edge compensation is being used to maximize system efficiency, and minimize stray heating of the reaction armature. Each stage will output approximately 60 kN of force and produce over 500 G s of acceleration on the armature. The advantage of this design is there is no ablation to the projectile and no sliding contacts, allowing repeated firing of the launcher without maintenance of any sort. The paper shows results of a parametric study for 500 m/s and 1,500 m/s linear induction launchers incorporating two of the latest compensation techniques for an air-core stator primary and an iron-core primary winding. Typical thrust densities for these machines are in the range of 150 kN/sq.m. to 225 kN/sq.m. and these compete favorably with permanent magnet linear synchronous machines. The operational advantages of the high speed SCIM launcher are shown by eliminating the need for pole-angle position sensors as would be required by synchronous systems. The stator power factor is also improved.

Kuznetsov, Stephen↗
NASA NTRS2009

Rapid Monitoring of Bacteria and Fungi aboard the International Space Station (ISS)

Microorganisms within spacecraft have traditionally been monitored with culture-based techniques. These techniques involve growth of environmental samples (cabin water, air or surfaces) on agar-type media for several days, followed by visualization of resulting colonies or return of samples to Earth for ground-based analysis. Data obtained over the past 4 decades have enhanced our understanding of the microbial ecology within space stations. However, the approach has been limited by the following factors: i) Many microorganisms (estimated > 95%) in the environment cannot grow on conventional growth media; ii) Significant time lags (3-5 days for incubation and up to several months to return samples to ground); iii) Condensation in contact slides hinders colony counting by crew; and iv) Growth of potentially harmful microorganisms, which must then be disposed of safely. This report describes the operation of a new culture-independent technique onboard the ISS for rapid analysis (within minutes) of endotoxin and beta-1, 3-glucan, found in the cell walls of gramnegative bacteria and fungi, respectively. The technique involves analysis of environmental samples with the Limulus Amebocyte Lysate (LAL) assay in a handheld device, known as the Lab-On-a-Chip Application Development Portable Test System (LOCAD-PTS). LOCADPTS was launched to the ISS in December 2006, and here we present data obtained from Mach 2007 until the present day. These data include a comparative study between LOCADPTS analysis and existing culture-based methods; and an exploratory survey of surface endotoxin and beta-1, 3-glucan throughout the ISS. While a general correlation between LOCAD-PTS and traditional culture-based methods should not be expected, we will suggest new requirements for microbial monitoring based upon culture-independent parameters measured by LOCAD-PTS.

Gunter, D.↗
NASA NTRS2009

Intermetallic Nickel-Titanium Alloys for Oil-Lubricated Bearing Applications

An intermetallic nickel-titanium alloy, NITINOL 60 (60NiTi), containing 60 wt% nickel and 40 wt% titanium, is shown to be a promising candidate material for oil-lubricated rolling and sliding contact applications such as bearings and gears. NiTi alloys are well known and normally exploited for their shape memory behavior. When properly processed, however, NITINOL 60 exhibits excellent dimensional stability and useful structural properties. Processed via high temperature, high-pressure powder metallurgy techniques or other means, NITINOL 60 offers a broad combination of physical properties that make it unique among bearing materials. NITINOL 60 is hard, electrically conductive, highly corrosion resistant, less dense than steel, readily machined prior to final heat treatment, nongalling and nonmagnetic. No other bearing alloy, metallic or ceramic encompasses all of these attributes. Further, NITINOL 60 has shown remarkable tribological performance when compared to other aerospace bearing alloys under oil-lubricated conditions. Spiral orbit tribometer (SOT) tests were conducted in vacuum using NITINOL 60 balls loaded between rotating 440C stainless steel disks, lubricated with synthetic hydrocarbon oil. Under conditions considered representative of precision bearings, the performance (life and friction) equaled or exceeded that observed with silicon nitride or titanium carbide coated 440C bearing balls. Based upon this preliminary data, it appears that NITINOL 60, despite its high titanium content, is a promising candidate alloy for advanced mechanical systems requiring superior and intrinsic corrosion resistance, electrical conductivity and nonmagnetic behavior under lubricated contacting conditions.

DellaCorte, C.↗
NASA NTRS2008

LOCAD-PTS: Operation of a New System for Microbial Monitoring Aboard the International Space Station (ISS)

Microorganisms within the space stations Salyut, Mir and the International Space Station (ISS), have traditionally been monitored with culture-based techniques. These techniques involve growing environmental samples (cabin water, air or surfaces) on agar-type media for several days, followed by visualization of resulting colonies; and return of samples to Earth for ground-based analysis. This approach has provided a wealth of useful data and enhanced our understanding of the microbial ecology within space stations. However, the approach is also limited by the following: i) More than 95% microorganisms in the environment cannot grow on conventional growth media; ii) Significant time lags occur between onboard sampling and colony visualization (3-5 days) and ground-based analysis (as long as several months); iii) Colonies are often difficult to visualize due to condensation within contact slide media plates; and iv) Techniques involve growth of potentially harmful microorganisms, which must then be disposed of safely. This report describes the operation of a new culture-independent technique onboard the ISS for rapid analysis (within minutes) of endotoxin and -1, 3-glucan, found in the cell walls of gram-negative bacteria and fungi, respectively. This technique involves analysis of environmental samples with the Limulus Amebocyte Lysate (LAL) assay in a handheld device. This handheld device and sampling system is known as the Lab-On-a-Chip Application Development Portable Test System (LOCAD-PTS). A poster will be presented that describes a comparative study between LOCAD-PTS analysis and existing culture-based methods onboard the ISS; together with an exploratory survey of surface endotoxin throughout the ISS. It is concluded that while a general correlation between LOCAD-PTS and traditional culture-based methods should not necessarily be expected, a combinatorial approach can be adopted where both sets of data are used together to generate a more complete story of the microbial ecology on the ISS.

Maule, J.↗
NASA NTRS2009

NASA PS400: A New Temperature Solid Lubricant Coating for High Temperature Wear Applications

A new solid lubricant coating, NASA PS400, has been developed for high temperature tribological applications. This plasma sprayed coating is a variant of the patented PS304 coating and has been formulated to provide higher density, smoother surface finish and better dimensional stability than PS304. PS400 is comprised of a nickel-molybdenum binder that provides strength, creep resistance and extreme oxidative and dimensional stability. Chromium oxide, silver and barium-calcium fluoride eutectic are added to the binder to form PS400.Tribological properties were evaluated with a pin-on-disk test rig in sliding contact to 650 C. Coating material samples were exposed to air, argon and vacuum at 760 C followed by cross section microscopic analysis to assess microstructure stability. Oil-Free microturbine engine hot section foil bearing tests were undertaken to assess PS400 s suitability for hot foil gas bearing applications. The preliminary results indicate that PS400 exhibits tribological characteristics comparable to the PS304 coating but with enhanced creep resistance and dimensional stability suitable for demanding, dynamic applications.

DellaCorte, C.↗
NASA NTRS2010

Turbopump Seal Testing at Marshall Space Flight Center

The new ARES space flight program has presented many challenges to aerospace engineers and designers. One of the areas for consideration are the seals in the turbopumps that supply cryogenic propellants to the combustion chamber in the upper stage. Heritage face seals that worked in the past might not be sufficient in the newer turbopumps with increased speeds, pressures across the seals, and loads. New seal materials, engineering designs, and analysis techniques have been developed since the early use of these heritage seals, however, rub conditions and surface degradation at the sliding contact cannot be reliably predicted. Testing is required to determine the safe operating limits and verify seal wear life over the operating range. Rocketdyne in Canoga Park California entered into a task agreement with MSFC to design, fabricate, build, test, disassemble, and inspect hardware after tests of carbon materials and wear resistant coatings. The purpose of testing would be to determine the safe operating limits, empirically iterate the design, and select the best combination of materials for face seals and mating rings. This paper summarizes the many hours and efforts of individuals and teams to get the program operating successfully and presents the test results that were obtained.

Gibson, Howard G.↗
NASA NTRS2000

Microbiological Contamination of Spacecraft

The International Space Station (ISS) Phase1 Program resulted in seven US astronauts residing aboard the Russian Space Station Mir between March 1995 and May 1998. Collaboration between U.S. and Russian scientists consisted of collection and analyses of samples from the crewmembers and the Mir and Shuttle environments before, during, and after missions that lasted from 75 to 209 days in duration. The effects of long-duration space flight on the microbial characteristics of closed life support systems and the interactions of microbes with the spacecraft environment and crewmembers were investigated. Air samples were collected using a Russian or U.S.-supplied sampler (SAS, RCS, or Burkard,) while surface samples were collected using contact slides (Hycon) or swabs. Mir recycled condensate and stored potable water sources were analyzed using the U.S.-supplied Water Experiment Kit. In-flight analysis consisted of enumeration of levels of bacteria and fungi. Amounts of microorganisms seen in the air and on surfaces were mostly within acceptability lin1its; observed temporal fluctuations in levels of microbes probably reflect changes in environmental conditions (e.g., humidity). All Mir galley hot water samples were within the standards set for Mir and the ISS. Microbial isolates were returned to Earth for identification of bacterial and fungal isolates. Crew samples (nose, throat, skin, urine, and feces) were analyzed using methods approved for the medical evaluations of Shuttle flight crews. No significant changes in crew microbiota were found during space flight or upon return relative to preflight results. Dissemination of microbes between the crew and environment was demonstrated by D A fingerprinting. Some biodegradation of spacecraft materials was observed. Accumulation of condensate allowed for the recovery of a wide range of bacteria and fungi as well as some protozoa and dust mites.

Pierson, D. L.↗
NASA NTRS2009

Foil Bearing Starting Considerations and Requirements for Rotorcraft Engine Applications

Foil gas bearings under development for rotorcraft-sized, hot core engine applications have been susceptible to damage from the slow acceleration and rates typically encountered during the pre-ignition stage in conventional engines. Recent laboratory failures have been assumed to be directly linked to operating foil bearings below their lift-off speed while following conventional startup procedures for the engines. In each instance, the continuous sliding contact between the foils and shaft was believed to thermally overload the bearing and cause the engines to fail. These failures highlight the need to characterize required acceleration rates and minimum operating speeds for these applications. In this report, startup experiments were conducted with a large, rotorcraft engine sized foil bearing under moderate load and acceleration rates to identify the proper start procedures needed to avoid bearing failure. The results showed that a bearing under a 39.4 kPa static load can withstand a modest acceleration rate of 500 rpm/s and excessive loitering below the bearing lift-off speed provided an adequate solid lubricant is present.

Radil, Kevin C.↗
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↗
NASA NTRS1982

The influence of surface dents and grooves on traction in sliding EHD point contacts

Changes in traction, caused by dents and grooves on a highly polished ball,are investigated as these defects approach and go through sliding elastohydrodynamic point contacts. The contacts are formed with the ball loading against a transparent disk. The ball and thus the topographical features are held stationary at various locations in the vicinity and within the contact while the disk is rotating. These topographical features can cause substantial changes in the traction when compared to traction obtained with smooth surfaces.

Cusano, C.↗
NASA NTRS1983

The influence of surface dents and grooves on traction in sliding EHD point contacts

Changes in traction, caused by dents and grooves on a highly polished ball, are investigated as these defects approach and go through sliding elastohydrodynamic point contacts. The contacts are formed with the ball loading against a transparent disk. The ball and thus the topographical features are held stationary at various locations in the vicinity and within the contact while the disk is rotating. These topographical features can cause substantial changes in the traction when compared to traction obtained with smooth surfaces. Previously announced in STAR as N82-32734

Cusano, C.↗
NASA NTRS1972

Optical interferometry study of film formation in lubrication of sliding and/or rolling contacts

Seventeen fluids of widely varying physical properties and molecular structure were chosen for study. Film thickness and traction were measured simultaneously in point contacts by interferometry, from which a new theory of traction was proposed. Film thickness was measured in line contacts by interferometry and electrical capacitance to establish correlation between these two methods. An interferometric method for the absolute determination of refractive index in the contact zone was developed and applied to point contact fluid entrapments. Electrical capacitance was used to study the thickness and properties of the soft surface film which sometimes forms near a metal-fluid interface.

Stejskal, E. O.↗
NASA NTRS1995

Sensitivity analysis of frictional contact response of axisymmetric composite structures

A computational procedure is presented for evaluating the sensitivity coefficients of the static frictional contact response of axisymmetric composite structures. The structures are assumed to consist of an arbitrary number of perfectly bonded homogeneous anisotropic layers. The material of each layer is assumed to be hyperelastic, and the effect of geometric nonlinearity is included. The sensitivity coefficients measure the sensitivity of the response variations in different material, lamination and geometric parameters of the structure. A displacement finite element model is used for the discretization. The normal contact conditions are incorporated into the formulation by using a perturbed Lagrangian approach with the fundamental unknowns consisting of nodal displacements, and Lagrange multipliers associated with the contact conditions. The Lagrange multipliers are allowed to be discontinuous at interelement boundaries. Tangential contact conditions are incorporated by using a penalty method in conjunction with the classical Coulomb's friction model. The Newton-Raphson iterative scheme is used for the solution of the resulting nonlinear algebraic equations, and for the determination of the contact region, contact conditions (sliding or sticking), and the contact pressures. The sensitivity coefficients are evaluated by using a direct differentiation approach. Numerical results are presented for the frictional contact of a composite spherical cap pressed against a rigid plate.

Karaoglan, I.↗