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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 217 records · Page 12
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Non-equilibrium molecular dynamics studies of thermal diffusion of hydrogen isotopes in low concentration zirconium hydrides

Tritium permeability in zirconium-based tritium getter critically impacts tritium storage and environmental safety during operation of tritium-producing burnable absorber rods (TPBARs). Previous experiments indicated that during irradiation operation, the hydrogen equilibrium pressured is increased. Further experimental and modeling studies suggested that the enhanced tritium release observed for reactor scale assemblies might be related to a thermal diffusion known as the Soret effect. A direct measurement of the Soret factor, however, has not been performed. To improve TPBAR and other nuclear applications, here we have applied two non-equilibrium molecular dynamics methods to study thermal diffusion of hydrogen isotopes in low-concentration zirconium hydrides. One of the methods produces sufficiently converged results to distinguish crystal orientation, isotope type, and concentration effects. In conclusion, with this method, crystal orientation, isotope type, and concentration effects are discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Europium diffusion in IG-110 nuclear graphite

Europium diffusion in graphite has been recognized to be of interest in high-temperature gas reactor safety analysis, particularly as an indicator of strontium diffusion. However, no measurements of europium diffusion coefficients have been reported in the literature. In this work, the effective diffusion coefficient of europium was measured using a time-release method. Natural europium was loaded into pre-milled unirradiated IG-110 graphite spheres using a pressurized acid digestion vessel. The time-release experiments were performed in the temperature range 1823 K – 1973 K using a SiC diffusion cell connected to an inductively-coupled plasma mass spectrometer (ICP-MS) via a He gas line. Finally, the results of this work are: D Eu, IG-110 = (1.5 x 10 -3 m 2 /s) exp $(\frac{-2.87\mathrm{x}10^{5} J/mol}{RT})$ This effective diffusion coefficient can be used to aid in predictive modelling of europium transport in HTGRs.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Performance of the Initial Implementation of the Shift Monte Carlo Code in SCALE 6.3

The Shift Monte Carlo code will be introduced in SCALE 6.3 as an alternative to the KENO V.a, KENO-VI, and Monaco codes. Calculations were performed to establish the performance of Shift for criticality safety analyses within the criticality safety analyses sequence (CSAS) based on models in the Verified, Archived Library of Inputs and Data (VALID). This test suite contains over 600 critical experiment models covering a broad range of fissile materials and neutron energy spectra. The comparisons presented include calculated k eff values and runtime performance for serial calculations and a selection of parallel calculations. Comparisons are presented for multigroup (MG) and continuous-energy (CE) calculations for KENO V.a and KENO-VI models. Results generated with a beta version of SCALE 6.3 indicate excellent agreement in k eff values between KENO and Shift. The largest differences in the average k eff value calculated for the 15 categories of KENO V.a models are 0.00020 ± 0.00011 Δ k for MG calculations and 0.00011 ± 0.00005 Δ k for CE calculations. Similar comparisons in three categories using KENO-VI result in the largest differences for MG calculations: as 0.00004 ± 0.00003 Δ k , and -0.00002 ± 0.00003 Δ k for CE. The preliminary results also indicate that Shift is faster than KENO on a per particle basis, especially for fast spectrum systems. The uncertainty per history is also higher, however, so the Monte Carlo figure of merit is higher for KENO for thermal and intermediate spectrum systems. As expected, Shift generally has better speedup than KENO for parallel calculations, regardless of neutron energy spectrum.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2026

Improvement of Drop‐Hammer Impact Testing for Safety Assessment of High Explosives Using 10‐mg Samples

Here, in this study, we established an improved method for drop-hammer impact testing of small quantities of high explosives (10 mg). We performed about seven hundred impact tests under various experimental conditions (e.g., sandpaper vs bare anvil, different sample masses, drop-weights, and striker diameters) to determine an optimal set of conditions and reaction detection methods (e.g., gas analysis, video, and sound recordings) that give the most statistically reliable results with 10 mg samples. We used both Frequentist and Bayesian statistical approaches to compare estimates of the drop height (DH50) that initiates a reaction 50% of the time, and to quantify the associated uncertainty. Gas analysis proved to be the most reliable reaction detection method, showing unambiguous rises in HE decomposition products (e.g., CO 2 ) even when the other indicators (e.g., sound, video) were inconclusive. The impact tests performed with a bare anvil showed much better reproducibility than those conducted with sandpaper, reducing the largest uncertainty observed in the data sets by a factor of 1.7. The DH 50 values obtained from three different sample masses (10, 20, and 35 mg) fell within the uncertainties of the measurements. We demonstrated the improved procedure (i.e., 10-mg samples, gas analysis, bare anvil, and Bayesian approach) on a variety of PETN samples having different surface areas and thermal histories.

PETN↗
DOE OSTI2021

Calculated Roughness Changes due to Clear-Cutting At Savannah River Site

At the Savannah River Site (SRS), multiple facilities are routinely producing and working with radiological constituents which require safety basis modeling by the National Nuclear Safety Administration. The models used to determine the safety basis employ roughness length as an input parameter which describes the roughness of the ground surface which influences momentum exchange near the surface and the subsequent generation of mechanical turbulence. Because roughness length is dependent on surface characteristics, including vegetation, any changes to the surface would have a subsequent impact on the roughness length and require a new safety basis analysis to be performed. An analysis of measurements prior to and after the dear-cuts and thinning was performed and roughness lengths were calculated for each of sixteen wind sectors. Not all sectors contained dear-cuts, so this provides comparison of natural variations in roughness. Based on the results of the estimated changes, consideration will be given to how these changes may affect atmospheric dispersion modeling. It was found that clear-cutting activities generally led to a reduction in roughness. Reductions in roughness length also occurred in some of the wind sectors containing only undisturbed forest, but those in sectors with dear-cuts were found to be slightly greater in magnitude than natural variation. Only in one instance was the change in roughness length found to exceed a decrease of 10%, indicating that there is no significant safety basis to the site as a whole based on previous clear-cutting activities.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

Automated Inspection of Criticality Control Overpacks for Surplus Plutonium Disposition: Qualification Update – 25313

In an effort to reduce the amount of nuclear waste in South Carolina, the Department of Energy (DOE) tasked the Savannah River Site (SRS) with diluting and disposing of the amount of plutonium in the state. This process involves the movement and shipment of over 100,000 criticality control overpacks (CCOs) throughout the project lifespan, lending itself to the use of automation to reduce worker radiation exposure and more efficiently utilize human capital. Due to the large scope, this overarching process was broken down into several different “automation projects” to be developed. The first opportunity pursued was the receipt and inspection of empty CCO drums coming into SRS, identified as Automation Project 1 (AP1), and is the focus of this paper. AP1 was developed to unpack incoming CCOs and inspect them for unwanted foreign objects and any damage to the drum or its contents. This process is accomplished by the combination of an automated guided vehicle (AGV) that delivers CCOs to a robotic arm which uses a suite of custom tools to disassemble a CCO, inspect the inside and outside of the CCO and its inner criticality control container (CCC), reassemble the CCC and CCO, and apply a tamper indicating device (TID) to the inspected drum. In past years, the robotic work cell had been developed in a small-scale testing facility for proof-of-concept. This year, major improvements were made to the robotic work cell to perform the process, including integration into the final facility where CCOs will be inspected. Other technical improvements include the implementation of sensor feedback and safety relays into the control system to allow the state of the work cell to be better tracked, and additional development of the TID application process to complete the robotic inspection. Further enhancements were made to the robotic vision processes and robot pathing, as well as development on a computer vision inspection process to detect inspection criteria anomalies in CCOs. In addition to developmental improvements, the work cell underwent a six-month testing period to ensure the project requirements were met. Results of this testing period demonstrate the work cell’s capability to meet project throughput goals at an acceptable level, successfully document the status of each CCO inspected, and reduce the toll on technical operations’ human power by two thirds. At the time of this paper, the work cell is capable of autonomously handling up to eight CCOs with an AGV, delivering CCOs to and from the robot work cell, and having a robotic arm perform a full receipt and inspection procedure on each CCO. Moving forward, repeatability will be improved so that these CCOs can be run back-to-back seamlessly, as well as improving the system to handle more significant edge cases and failure modes.

Spivey, Nicholas↗
DOE OSTI2022

Multigroup Examination of Nickel-Reflected HEU System

Critical configurations of HEU-MET-FAST-003 (HMF-003) from the International Criticality Safety Benchmark Evaluation Project Handbook were modeled for addition into the Verified, Archived Library of Inputs and Data maintained at Oak Ridge National Laboratory. HMF-003 contains models of a highly enriched uranium sphere with a spherical metal reflector of natural uranium, tungsten carbide, or nickel. For these simple models, good agreement is expected between the k eff calculated with continuous-energy (CE) and multigroup (MG) transport. However, using the CSAS5 sequence of the SCALE 6.2.4 package, the 8 in. thick nickel reflector model resulted in a difference of around 1.2 % Δ k . Results presented a clear indication of poor performance for the SCALE 252-group based on ENDF/B-VII.1 cross section library for this model. The bias was investigated over a range of nickel thickness and then compared with other MG libraries available in SCALE 6.2.4. As the nickel thickness increases, the MG k eff deviates from the CE result, confirming a performance issue with the MG calculation. Additionally, the reactions were compared between the two libraries to help determine the cause of k eff bias. Finally, additional MG libraries within SCALE 6.3 and based on ENDF/B-VII.1 and ENDF/B-VIII were reviewed. The 302-group and 1597-group result in significant improvements compared with the 252-group library. Nickel cross sections were modified from ENDF/B-VII.1 to ENDF/B-VIII. For the ENDF/B-VIII library, the deviation between the CE libraries and MG libraries is less pronounced than for ENDF/VII.1, except for the 1597-group. This examination clearly indicates the importance of validating calculations with applicable benchmark experiments and caution when using MG libraries.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2023

Experimental investigation of power transient flow boiling

To advance the mechanistic understanding of power transients in flow boiling, experimental investigations are performed to capture the thermal response of four different kinds of cladding materials, including FeCrAls, to Fuchs reactivity initiated accident transients and linear ramp power transients. The transition boiling regime is phenomenologically reflected in power-transient flow boiling, which is different from steady-state boiling. In light of this, the critical heat flux that is usually featured with temperature overshooting does not indicate thermal safety margin of cladding materials as conservatively as the maximum heat flux, which is greater than critical heat flux in the power transient boiling curve. This is physically attributed to the thermal energy deposition on the cladding wall. In addition, the thermal energy released from the cladding wall results in different boiling heat transfer coefficient for the decreasing and increasing power stages respectively during the Fuchs power transient. The maximum heat flux difference gap, which appears due to changes in cladding materials and transient time scales, is appreciable under an intermediate heat convection regime. However, this difference gap is gradually weakened by the progressive increasing of mass flux and/or inlet subcooling due to the enhanced dominance of heat convection over heat conduction. Finally, the small difference gap of maximum heat flux is found to be insignificant under the weak heat convection because of power transient induced annular flow instability.

42 ENGINEERING↗
NASA NTRSDate not supplied

Lunar Search & Rescue Applications of Lunar GNSS

Accurate lunar navigation and timing knowledge provides for the development of safety-critical services in the cislunar and lunar surface domain. Currently under development, the Goddard Space Flight Center’s (GSFC) Search and Rescue Mission Office is investigating and integrating search and rescue (SAR) capability into planned and future lunar communication and navigation interfaces. Lunar Search and Rescue (LunaSAR) development has a stated end-goal for assured, reliable, and timely indication of distress events for a wide variety of lunar surface users, including government-sponsored, commercial, and international users. LunaSAR performance requirements are modelled after the current terrestrial Cospas-Sarsat distress notification system, leveraging an internationally robust global navigation satellite system (GNSS) ecosystem as a core element of survivor locating capability. This presentation will discuss NASA’s work to develop user-focused distress messaging capabilities including infusion of example sensor data for triggering of automated distress alerts coupled with location-tagging. Additionally, the presentation will examine overall message structures, rotating fields for use in bi-directional distress messaging, and specific use cases based on NASA’s lunar exploration and lunar communication relay architectures. Modelling and simulation of LunaSAR use by individual lunar explorers will be discussed, based on notional industry and government design reference missions and mission considerations. Results from GSFC-funded Internal Research and Development (IRAD) efforts will be detailed, including successful distress message formulation simulating the ingestion of example legacy space suit telemetry fields. Hardware-in-the-loop testing using high-reliability software defined radio (SDR) modules serve as an example of IRAD successes and the framework for technical requirements. Architectural development and technical evolution from 2020 to 2021 included alignment of LunaSAR distress waveforms with ongoing NASA LunaNet interoperability development, as well as engagement with NASA Lunar Spectrum authorities for allocation of UHF-band distress frequencies on the lunar surface. S-Band and UHF-band transmission characteristics will be detailed, along with band-specific applications of each emission type. Additionally, examples of ingestion and formatting of GNSS signals (using historical terrestrial National Marine Electronics Association-formatted GNSS data) will be detailed, underscoring lunar user needs for a common lunar GNSS receiver output message framework. Maturity and ability to support evolving lunar exploration goals has been demonstrated and will be detailed, with maturity gaps such as position, navigation, and timing (PNT) and lunar reference frames identified within the context of distress message generation. Provision of LunaSAR services for lunar surface users represents a new era of ensured safety for lunar explorers and builds off of forty years of the Cospas-Sarsat program, underscoring the importance of lunar GNSS for safety-critical applications and growing interest in safe, reliable lunar surface operations. Enabled by new GNSS systems being developed by government and industry partners, NASA will continue to evolve and integrate lunar GNSS types into distress message generation, with a focus on compact and efficient message transmission over various lunar communication links. When fielded, LunaSAR will be the first dedicated search and rescue notification system employed on another celestial body. Robust lunar navigation and timing services form the core of LunaSAR capabilities, allowing for system syncing with time-dominant sensors, and high-accuracy location of those in distress while engaged in lunar surface activities.

Search and Rescue↗
NASA NTRS2013

High Speed Mobility Through On-Demand Aviation

Game changing advances come about by the introduction of new technologies at a time when societal needs create the opportunity for new market solutions. A unique opportunity exists for NASA to bring about such a mobility revolution in General Aviation, extendable to other aviation markets, to maintain leadership in aviation by the United States. This report outlines the research carried out so far under NASA's leadership towards developing a new mobility choice, called Zip Aviation1,2,3. The feasibility, technology and system gaps that need to be addressed, and pathways for successful implementation have been investigated to guide future investment. The past decade indicates exciting trends in transportation technologies, which are quickly evolving. Automobiles are embracing automation to ease driver tasks as well as to completely control the vehicle with added safety (Figure 1). Electric propulsion is providing zero tail-pipe emission vehicles with dramatically lower energy and maintenance costs. These technologies have not yet been applied to aviation, yet offer compelling potential benefits across all aviation markets, and in particular to General Aviation (GA) as an early adopter market. The benefits of such an adoption are applicable in the following areas: 􀁸 Safety: The GA market experiences accident rates that are substantially higher than automobiles or commercial airlines, with 7.5 fatal accidents per 100 million vehicle miles compared to 1.3 for automobiles and.068 for airlines. Approximately 80% of these accidents are caused by some form of pilot error, with another 13% caused by single point propulsion system failure. 􀁸 Emissions: Environmental constraints are pushing for the elimination of 100Low Lead (LL) fuel used in most GA aircraft, with aviation fuel the #1 source of lead emissions into the environment. Aircraft also have no emission control systems (i.e. no catalytic converters etc.), so they are gross hydrocarbon polluters compared to automobiles. 􀁸 Community Noise: Hub and smaller GA airports are facing increasing noise restrictions, and while commercial airliners have dramatically decreased their community noise footprint over the past 30 years, GA aircraft noise has essentially remained same, and moreover, is located in closer proximity to neighborhoods and businesses. 􀁸 Operating Costs: GA operating costs have risen dramatically due to average fuel costs of over $6 per gallon, which has constrained the market over the past decade and resulted in more than 50% lower sales and 35% less yearly operations. Infusion of autonomy and electric propulsion technologies can accomplish not only a transformation of the GA market, but also provide a technology enablement bridge for both larger aircraft and the emerging civil Unmanned Aerial Systems (UAS) markets. The NASA Advanced General Aviation Transport Experiments (AGATE) project successfully used a similar approach to enable the introduction of primary composite structures and flat panel displays in the 1990s, establishing both the technology and certification standardization to permit quick adoption through partnerships with industry, academia, and the Federal Aviation Administration (FAA). Regional and airliner markets are experiencing constant pressure to achieve decreasing levels of community emissions and noise, while lowering operating costs and improving safety. But to what degree can these new technology frontiers impact aircraft safety, the environment, operations, cost, and performance? Are the benefits transformational enough to fundamentally alter aircraft competiveness and productivity to permit much greater aviation use for high speed and On-Demand Mobility (ODM)? These questions were asked in a Zip aviation system study named after the Zip Car, an emerging car-sharing business model. Zip Aviation investigates the potential to enable new emergent markets for aviation that offer "more flexibility than the existing transportation solutions." These studies indicate that autonomy and electric propulsion technology infusions offer a unique opportunity to provide breakthrough capabilities for new high speed, on-demand travel alternatives that can leapfrog the need for future expensive ground-based infrastructure investment. At the same time, such investments offer a method of laying the foundation for these technologies to be incubated for commercial aviation at lower cost, and with lower initial certification thresholds due to the relatively poor capabilities of GA aircraft to permit early adoption and private market capitalization by rapid technology accelerations, as depicted in Figure 2.

Moore, Mark D.↗
DOE OSTI2024

Considerations for Improving the Technoeconomic Viability of Heat Pipe Microreactors by Employing a Functional Containment Approach

The economic cost of a microreactor is being investigated by leveraging MARVEL cost information in conjunction with some simplified design and analysis activities to present a hypothetical, yet feasible, option for investigation. This bottom-up cost estimate for a hypothetical commercial microreactor will be used to provide guidance to the industry and research communities regarding where priorities should be set to improve the viability of broad microreactor deployment. To support the design and analysis activities required to present a feasible option, some understanding of maximum accidental radionuclide releases and consequences is needed to provide bounding estimates on containment or confinement systems for radionuclide retention. To estimate fission product barrier and retention performance, a gaussian plume dose and dispersion model is employed, with isotopic inventories being propagated between barriers assuming conservative fractional release rates. Demonstrably conservative meteorological assumptions are also assumed. Standard reference release rates are assumed where safety requirements could be easily and economically employed. Results are provided in units of total effective dose equivalent as a function of distance from the release (i.e., the reactor). Initial results indicate that the hypothetical microreactor will likely need to credit the fuel cladding and at least one other barrier, or combination of barriers, to ensure public health and safety as required during a postulated accident. This approach is referred to as “functional containment,” since no single barrier will be relied upon for satisfying regulatory requirements and fundamental safety functions for radionuclide retention. Finally, a set of barrier options are provided so that future economic analyses can select the most viable design path.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS2008

Impact of Pilot Delay and Non-Responsiveness on the Safety Performance of Airborne Separation

Assessing the safety effects of prediction errors and uncertainty on automationsupported functions in the Next Generation Air Transportation System concept of operations is of foremost importance, particularly safety critical functions such as separation that involve human decision-making. Both ground-based and airborne, the automation of separation functions must be designed to account for, and mitigate the impact of, information uncertainty and varying human response. This paper describes an experiment that addresses the potential impact of operator delay when interacting with separation support systems. In this study, we evaluated an airborne separation capability operated by a simulated pilot. The experimental runs are part of the Safety Performance of Airborne Separation (SPAS) experiment suite that examines the safety implications of prediction errors and system uncertainties on airborne separation assistance systems. Pilot actions required by the airborne separation automation to resolve traffic conflicts were delayed within a wide range, varying from five to 240 seconds while a percentage of randomly selected pilots were programmed to completely miss the conflict alerts and therefore take no action. Results indicate that the strategicAirborne Separation Assistance System (ASAS) functions exercised in the experiment can sustain pilot response delays of up to 90 seconds and more, depending on the traffic density. However, when pilots or operators fail to respond to conflict alerts the safety effects are substantial, particularly at higher traffic densities.

Consiglio, Maria↗
DOE OSTI2022

Can disposable masks be worn more than once?

Disposable facemasks are a primary tool to prevent the transmission of SARS-COV-2 during the COVID-19 pandemic. However, plastic waste generated from their disposal represents a significant environmental problem that can be reduced by maximizing the service life of disposable masks. We evaluated the effect of repeated wearing on the fitted filtration efficiency (FFE) of N95, KF94, KN95, and procedure/surgical masks. The FFEs of masks were compared following extended wearing with and without washing. Results reveal that most disposable facemasks can retain a high level of their baseline FFE after extended wearing, even after 40 h of wearing. Laundering disposable masks degraded FFE in some instances. We conclude that the durability of disposable facemask performance is considerably longer than their intended single use indication, suggesting that reusing disposable masks is a safe means of reducing plastic waste in the environment.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2026

Capture, storage, and re-use of liquid hydrogen boil-off for aviation and aerospace applications

Despite major interest in the use of liquid hydrogen as a fuel for aviation and aerospace sectors, loss of hydrogen through boil-off continues to be a hurdle as it causes financial loss, indirect greenhouse gas emissions, and safety concerns. Herein, we perform techno-economic analysis, calibrated with experimental measurements, to assess the use of sorbents to capture and condition hydrogen boil-off events in the range of 1.5 to 70 tonnes per day at launch sites and airports. We evaluate the direct delivery of captured boil-off to combustion engines and fuel cells, comparing against boil-off re-liquification and compression. Results indicate probable cost-effectiveness at delivered liquid hydrogen prices above 0.9 U.S. dollar ($) per kg H2 at airports, and above 10 $ per kg H2 at launch sites where 10% or more of hydrogen is lost to boil-off.

08 HYDROGEN↗
NASA NTRS2007

Use of Thermoregulatory Models to Enhance Space Shuttle and Space Station operations and Review of Human Thermoregulatory Control

Thermoregulation in the space environment is critical for survival, especially in off- nominal operations. In such cases, mathematical models of thermoregulation are frequently employed to evaluate safety-of-flight issues in various human mission scenarious. In this study, the 225-node Wissler model and the 41-Node Metabolic Man model are employed to evaluate the effects of such a scenario. Metabolic loads on astronauts wearing the advanced crew escape suit (ACES) and liquid cooled ventilation garment (LCVG) are imposed on astronauts exposed to elevated cabin temperatures resulting from a systems failure. The study indicates that the performance of the ACES/LCVG cooling system is marginal. Increases in workload and or cabin temperature above nominal will increase rectal temperature, stored heat load, heart rate, and sweating, which could lead to deficits in the performance of cognitive and motor tasks. This is of concern as the ACES/LCVG is employed during Shuttle decent when the likelihood of a safe landing may be compromised. The study indicates that the most effective mitigation strategy would be to decrease the LCVG inlet temperature.

Pisacane, V. L.↗
NASA NTRS2015

Flight Test of a Head-Worn Display as an Equivalent-HUD for Terminal Operations

Research, development, test, and evaluation of flight deck interface technologies is being conducted by NASA to proactively identify, develop, and mature tools, methods, and technologies for improving overall aircraft safety of new and legacy vehicles operating in the Next Generation Air Transportation System (NextGen). Under NASA's Aviation Safety Program, one specific area of research is the use of small Head-Worn Displays (HWDs) as a potential equivalent display to a Head-up Display (HUD). Title 14 of the US CFR 91.175 describes a possible operational credit which can be obtained with airplane equipage of a HUD or an "equivalent"' display combined with Enhanced Vision (EV). A successful HWD implementation may provide the same safety and operational benefits as current HUD-equipped aircraft but for significantly more aircraft in which HUD installation is neither practical nor possible. A flight test was conducted to evaluate if the HWD, coupled with a head-tracker, can provide an equivalent display to a HUD. Approach and taxi testing was performed on-board NASA's experimental King Air aircraft in various visual conditions. Preliminary quantitative results indicate the HWD tested provided equivalent HUD performance, however operational issues were uncovered. The HWD showed significant potential as all of the pilots liked the increased situation awareness attributable to the HWD's unique capability of unlimited field-of-regard.

Shelton, K. J.↗
DOE OSTI2022

Results of ISO/TS 6336-22 Evaluating Full Contact Zone

ISO/TS 6336-22 (Calculation of load capacity of spur and helical gears - Part 22: Calculation of micropitting load capacity) is the ISO technical specification containing a proposal for calculations of the risk of micropitting in gear sets. Micropitting is a Hertzian fatigue phenomenon that appears as ultra-fine cracking and pitting on the flanks of gear teeth. Since progressive micropitting can lead to macropitting and flank damage, critical applications such as wind turbines, marine drives, and high-speed gear drives seek to accurately predict whether their designs are susceptible to this damage. ISO/TS 6336-22 assesses micropitting risk through a safety factor which is calculated as the minimum specific film thickness in the contact zone divided by a permissible specific film thickness. In the previous paper, the calculations were performed using the simplified method (Method B) that evaluates points on the path of contact. This was done for three gear sets that experienced micropitting in operation. The minimum specific film thickness for the two field cases was very high, which indicates that the gears were operating in the full elastohydrodynamic lubrication (EHL) regime. A more accurate calculation for these cases (Method A) calculates the specific film thickness across the entire contact zone. This paper applies this Method to the case study from the previous paper. The results are compared to micropitting observed in operation. Results are also compared to the results of the previous paper. Conclusions are made regarding the accuracy of both Methods compared to the field cases and relative to each other.

ENGINEERING,WIND ENERGY↗
DOE OSTI2022

Results of ISO/TS 6336-22 Evaluating Full Contact Zone: Preprint

ISO/TS 6336-22 (Calculation of load capacity of spur and helical gears — Part 22: Calculation of micropitting load capacity) is the ISO technical specification containing a proposal for calculations of the risk of micropitting in gear sets. Micropitting is a Hertzian fatigue phenomenon that appears as ultra-fine cracking and pitting on the flanks of gear teeth. Since progressive micropitting can lead to macropitting and flank damage, critical applications such as wind turbines, marine drives, and high-speed gear drives seek to accurately predict whether their designs are susceptible to this damage. ISO/TS 6336-22 assesses micropitting risk through a safety factor which is calculated as the minimum specific film thickness in the contact zone divided by a permissible specific film thickness. In the previous paper, the calculations were performed using the simplified method (Method B) that evaluates points on the path of contact. This was done for three gear sets that experienced micropitting in operation. The minimum specific film thickness for the two field cases was very high, which indicates that the gears were operating in the full elastohydrodynamic lubrication (EHL) regime. A more accurate calculation for these cases (Method A) calculates the specific film thickness across the entire contact zone. This paper applies this Method to the case study from the previous paper. The results are compared to micropitting observed in operation. Results are also compared to the results of the previous paper. Conclusions are made regarding the accuracy of both Methods compared to the field cases and relative to each other.

gearbox↗