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DOE OSTI2025

Friction and wear of nuclear graphite exposed to molten FLiNaK salt environment

This report formally documents the completion of the Advanced Reactor Technologies Level 3 Milestone (M3TG-25OR0501104), “Initiate graphite wear studies of graphite samples exposed to molten salt environment,” due August 1, 2025. The report summarizes the ongoing activities aimed at characterizing the friction and wear behavior of graphite in molten LiF–NaF–KF (FLiNaK) salt environment. The wear and friction behavior of self-mated ET-10 nuclear graphite were tested at varying temperatures (550°C and 650°C), contact loads (40 and 80 N) and sliding speeds (1 and 10 mm/s) in a controlled argon environment. The results were compared to the wear and friction behavior of the same graphite material in a dry argon environment. This report presents initial studies on the friction and wear behavior of graphite in sliding contact mode, with future work focused on investigating the graphite matrix materials, as well as rolling and impact contact modes. The outcomes of this report could provide insights into assessing the integrity of the graphitic components of pebble-bed fluoride salt–cooled high-temperature reactors (PB-FHRs) to enhance their safe operation.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS1985

Thermal traction contact performance evaluation under fully flooded and starved conditions

Ultra high speed traction tests were performed on two traction fluids commonly employed. Traction data on these fluids is required for purposes of traction drive design optimization techniques. To obtain the traction data, an existing twin disc traction test machine was employed. This machine was modified to accommodate the range of test variables. All the data reported was obtained under conditions of side slip, a technique whereby only low power levels are required to simulate real traction drive contacts. Theoretical traction predictions were performed for a representative number of curves that showed the influence of rolling velocity, of contact pressure and of aspect ratio. To establish the accuracy of the thermal model the predictions were performed ith increasing levels of independence of experimentally determined parameters. In the final resulting prediction only two non linear thermal parameters were used for the prediction of 15 different traction curves covering the entire range of variables as used in the investigation, with the exception of the influence of asperity traction. Comparison of these theoretical curves and corresponding experimental traces show very good agreement.

Tevaarwerk, J. L.↗

NASA NTRS1991

Quantifying oil filtration effects on bearing life

Rolling-element bearing life is influenced by the number, size, and material properties of particles entering the Hertzian contact of the rolling element and raceway. In general, rolling-element bearing life increases with increasing level of oil filtration. Based upon test results, two equations are presented which allow for the adjustment of bearing L(sub 10) or catalog life based upon oil filter rating. It is recommended that where no oil filtration is used catalog life be reduced by 50 percent.

Needelman, William M.↗

NASA NTRS1975

Silicon nitride used as a rolling-element bearing material

Rolling-element fatigue tests were conducted with hot-pressed silicon nitride to determine its ability to withstand concentrated contacts in rolling-element bearings. If hot-pressed silicon nitride is used for both balls and races, attention must be paid to fitting both shaft and bearing housing.

Parker, R. J.↗

NASA NTRS2018

Lifetimes of Multiply Alkylated Cyclopentane Oil in Contact with Various Metals, Evaluated with Vacuum Spiral Orbit Tribometer

The dependence of the lifetimes of small quantities of a Multiply Alkylated Cyclopentane (MAC) lubricant oil, Pennzane (Registered Trademark) 2001A (Nye Lubricants, Inc.), in rolling and sliding contact with different metals was evaluated with a vacuum spiral orbit tribometer. The metals were the bearing alloys 52100 steel, 440C steel, 17-4 PH steel and Nitinol 60 and the elements chromium, vanadium and titanium. The lifetimes of the lubricant oil on different metals fell into distinct groups with 52100 greater than 440C approx. Nitinol 60 greater than 17-4 PH for the order of the lifetimes of the steels and chromium greater than vanadium greater than titanium for the order of the lifetimes for the elements. The limited life of the small quantities of oil is assumed to be due to its consumption by the tribochemical reaction of the oil with the different metal bearing materials. The lifetimes are then inversely related to the reaction rates of the oil molecules with the various metals: the longest life of 52100 steel having the lowest reaction rate and the shortest life of titanium having the highest reaction rate. Mechanisms for the tribochemical reactions are discussed.

lubrication↗

DOE OSTI2020

Impact of the adhesion-force lever-arm “a” on the Rock ‘n’ Roll resuspension model and how to compute it from contact mechanics

The paper proposes a methodology to fill a gap in the context of mechanistic particle resuspension models related to the adhesion and lift force lever arms ( a ): to date, only one experimental observation exists from a centrifuge experiment with a specific particle/surface pair which found r P / a = 100 and assumed that the contact points were symmetric with respect to the particle center. However, the Reeks and Hall’s (2001) model is highly sensitive to this parameter, which therefore cannot be used as-is for different particle diameters or materials. This paper proposes a methodology to compute the adhesion and lift force lever arms ( a A and a L , respectively) based on Atomic Force Microcopy (AFM) surface roughness measurements and contact mechanics arguments. In practice, a spherical, perfectly smooth particle is brought in contact (computationally) with the measured surface roughness and is then rotated by the point of contact to determine the two or more asperities over which the particle would sit on the surface. A method to compute the asperity radius of curvature is devised to compute the asperity deformation and the correct partitioning of the total deformation between the particle and the asperity is presented. For the glass surface under consideration, the asperity deformation was negligible, i.e., it was below the van der Waals radius, which is the limit of applicability of contact mechanics. The Reeks and Hall’s (2001) model is then extended to account for the joint probability of a A and a L . Significant differences in particle resuspended after a day in common atmospheric conditions are found between the approach that uses the lever-arm distributions or their mean values. Also, important differences are found when comparing the lever-arm distribution and r P / a = 100. Hence, one should be cautious of using r P / a = 100 for surface/particle pairs differing from those in the original study. Finally, limits of applicability of the theories used are presented together with considerations regarding how to extend the method to non-spherical particles and different materials.

42 ENGINEERING↗

DOE OSTI2014

Rolling Element Bearing Stiffness Matrix Determination (Presentation)

Current theoretical bearing models differ in their stiffness estimates because of different model assumptions. In this study, a finite element/contact mechanics model is developed for rolling element bearings with the focus of obtaining accurate bearing stiffness for a wide range of bearing types and parameters. A combined surface integral and finite element method is used to solve for the contact mechanics between the rolling elements and races. This model captures the time-dependent characteristics of the bearing contact due to the orbital motion of the rolling elements. A numerical method is developed to determine the full bearing stiffness matrix corresponding to two radial, one axial, and two angular coordinates; the rotation about the shaft axis is free by design. This proposed stiffness determination method is validated against experiments in the literature and compared to existing analytical models and widely used advanced computational methods. The fully-populated stiffness matrix demonstrates the coupling between bearing radial, axial, and tilting bearing deflections.

17 WIND ENERGY↗

NASA NTRS1986

Solid lubrication design methodology, phase 2

The high temperature performance of solid lubricated rolling elements was conducted with a specially designed traction (friction) test apparatus. Graphite lubricants containing three additives (silver, phosphate glass, and zinc orthophosphate) were evaluated from room temperature to 540 C. Two hard coats were also evaluated. The evaluation of these lubricants, using a burnishing method of application, shows a reasonable transfer of lubricant and wear protection for short duration testing except in the 200 C temperature range. The graphite lubricants containing silver and zinc orthophosphate additives were more effective than the phosphate glass material over the test conditions examined. Traction coefficients ranged from a low of 0.07 to a high of 0.6. By curve fitting the traction data, empirical equations for slope and maximum traction coefficient as a function of contact pressure (P), rolling speed (U), and temperature (T) can be developed for each lubricant. A solid lubricant traction model was incorporated into an advanced bearing analysis code (SHABERTH). For comparison purposes, preliminary heat generation calculations were made for both oil and solid lubricated bearing operation. A preliminary analysis indicated a significantly higher heat generation for a solid lubricated ball bearing in a deep groove configuration. An analysis of a cylindrical roller bearing configuration showed a potential for a low friction solid lubricated bearing.

Pallini, R. A.↗

DOE OSTI2021

A Modular Mechanism for Downhole Weight-on-Bit and Torque Reaction in Small Diameter Boreholes

Drilling systems that use downhole rotation must react torque either through the drill-string or near the motor to achieve effective drilling performance. Problems with drill-string loading such as buckling, friction, and twist become more severe as hole diameter decreases. Therefore, for small holes, reacting torque downhole without interfering with the application of weight-on-bit, is preferred. In this paper, we present a novel mechanism that enables effective and controllable downhole weight on bit transmission and torque reaction. This scalable design achieves its unique performance through four key features: (1) mechanical advantage based on geometry, (2) direction dependent behavior using rolling and sliding contact, (3) modular scalability by combining modules in series, and (4) torque reaction and weight on bit that are proportional to applied axial force. As a result, simple mechanical devices can be used to react large torques while allowing controlled force to be transmitted to the drill bit. We outline our design, provide theoretical predictions of performance, and validate the results using full-scale testing. The experimental results include laboratory studies as well as limited field testing using a percussive hammer. These results demonstrate effective torque reaction, axial force transmission, favorable scaling with multiple modules, and predictable performance that is proportional to applied force.

15 GEOTHERMAL ENERGY↗

NASA NTRS1976

Bearing material

A composite material is described which will provide low friction surfaces for materials in rolling or sliding contact and is self-lubricating and oxidation resistant up to and in excess of about 930 C. The composite is comprised of a metal component which lends strength and elasticity to the structure, a fluoride salt component which provides lubrication and, lastly, a glass component which not only provides oxidation protection to the metal but may also enhance the lubrication qualities of the composite.

Sliney, H. E.↗

NASA NTRS1977

Microstructural and wear properties of sputtered carbides and silicides

Sputtered Cr3C2, Cr3Si2, and MoSi2 wear-resistant films (0.05 to 3.5 microns thick) were deposited on metal and glass surfaces. Electron transmission, electron diffraction, and scanning electron microscopy were used to determine the microstructural appearance. Strong adherence was obtained with these sputtered films. Internal stresses and defect crystallographic growth structures of various configurations within the film have progressively more undesirable effects for film thicknesses greater than 1.5 microns. Sliding contact and rolling-element bearing tests were also performed with these sputtered films.

Spalvins, T.↗

NASA NTRS1979

Method of making bearing materials

A method is described for making a composite material which provides low friction surfaces for materials in rolling or sliding contact. The composite material which is self-lubricating and oxidation resistant up to and in excess of about 930 C is comprised of a metal component which lends strength and elasticity to the structure and a fluorine salt component which provides oxidation protection to the metal but may also enhance the lubrication qualities of the composite.

Sliney, H. E.↗

NASA NTRS1980

Method of making bearing material

A composite material is described which will provide low friction surfaces for materials in rolling or sliding contact and is self lubricating and oxidation resistant up to and in excess of about 930 C. The composite is comprised of a metal component which lends strength and elasticity to the structure, a fluoride salt component which provides lubrication and, lastly, a glass component which not only provides oxidation protection to the metal but may also enhance the lubrication qualities of the composite.

Sliney, H. E.↗

NASA NTRS1981

Dynamics of solid dispersions in oil during the lubrication of point of contacts. Part 2: Molybdenum disulfide

A Hertzian contact consisting of a steel ball in contact with a glass disk is lubricated with MoS2 dispersions and observed by optical microscopy at various slide/roll conditions. In general the behavior of MoS2 and graphite are similar. That is, the solids tend to enter the contact and form a film on the contacting surfaces whenever a rolling component of motion is used, but solid particles seldom enter the contact during pure sliding. The MoS2 has more pronounced plastic flow behavior than graphite. However, the polished steel ball is more readily scratched by MoS2 than by graphite. Under the conditions of these studies, lower friction and wear are observed with pure oil rather than with the dispersions. However under other conditions (such as different contact geometry or rougher surfaces) the solid lubricant dispersions might be beneficial.

Cusano, C.↗

NASA NTRS1982

Heat generation in aircraft tires under free rolling conditions

A method was developed for calculating the internal temperature distribution in an aircraft tire while free rolling under load. The method uses an approximate stress analysis of each point in the tire as it rolls through the contact patch, and from this stress change the mechanical work done on each volume element may be obtained and converted into a heat release rate through a knowledge of material characteristics. The tire cross-section is then considered as a body with internal heat generation, and the diffusion equation is solved numerically with appropriate boundary conditions of the wheel and runway surface. Comparison with data obtained with buried thermocouples in tires shows good agreement.

Clark, S. K.↗

NASA NTRS1983

Traction behavior of two traction lubricants

In the analysis of rolling-sliding concentrated contacts, such as gears, bearings and traction drives, the traction characteristics of the lubricant are of prime importance. The elastic shear modulus and limiting shear stress properties of the lubricant dictate the traction/slip characteristics and power loss associated with an EHD contact undergoing slip and/or spin. These properties can be deducted directly from the initial slope m and maximum traction coefficient micron of an experimental traction curve. In this investigation, correlation equations are presented to predict m and micron for two modern traction fluids based on the regression analysis of 334 separate traction disk machine experiments. The effects of contact pressure, temperature, surface velocity, ellipticity ratio are examined. Problems in deducing lubricant shear moduli from disk machine tests are discussed.

Loewenthal, S. H.↗

NASA NTRS1983

Heat generation in aircraft tires

Clark, S. K.↗

NASA NTRS1984

Behaviors of Polymer Additives Under EHL and Influences of Interactions Between Additives on Friction Modification

Polymer additives have become requisite for the formulation of multigrade engine oils. The behavior of polymethacrylate (PMA)-thickened oils as lubricants in concentrated contacts under nominal rolling and pure sliding conditions was investigated by conventional optical interferometry. The PMA thickened oils behaved differently from the base oil in the formation of elastohydrodynamic (EHL) films. The higher the elastohydrodynamic molecular weight of the PMA contained in the lubricant, the thinner was the oil film under EHL conditions. The film thickness of shear-degraded PMA-thickened oils was also investigated. The behavior of graphite particles dispersed in both the base oil and the PMA-thickened oil was studied under pure sliding by taking photomicrographs. Many kinds of additives are contained in lubricating oil and the interactions between additives are considered. The interactions of zinc-organodithiophosphates (ZDP) with other additives is discussed.

Sakurai, T.↗