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Under contract with Marshall Space Flight Center, Midwest Research Institute compiled a Lubrication Handbook intended as a reference source for designers and manufacturers of aerospace hardware and crews responsible for maintenance of such equipment. Engineers of Lindsay Manufacturing Company learned of this handbook through NASA Tech Briefs and used it for supplemental information in redesigning gear boxes for their center pivot agricultural irrigation system.
A proposed microelectromechanical system (MEMS) containing a closed- Brayton-cycle turbine would serve as a prototype of electric-power generators for special applications in which high energy densities are required and in which, heretofore, batteries have been used. The system would have a volume of about 6 cm3 and would operate with a thermal efficiency >30 percent, generating up to 50 W of electrical power. The energy density of the proposed system would be about 10 times that of the best battery-based systems now available, and, as such, would be comparable to that of a fuel cell. The working gas for the turbine would be Xe containing small quantities of CO2, O2, and H2O as gaseous lubricants. The gas would be contained in an enclosed circulation system, within which the pressure would typically range between 5 and 50 atm (between 0.5 and 5 MPa). The heat for the Brayton cycle could be supplied by any of a number of sources, including a solar concentrator or a combustor burning a hydrocarbon or other fuel. The system would include novel heat-transfer and heat-management components. The turbine would be connected to an electric power generator/starter motor. The system would include a main rotor shaft with gas bearings; the bearing surfaces would be made of a ceramic material coated with nanocrystalline diamond. The shaft could withstand speed of 400,000 rpm or perhaps more, with bearing-wear rates less than 10(exp -)4 those of silicon bearings and 0.05 to 0.1 those of SiC bearings, and with a coefficient of friction about 0.1 that of Si or SiC bearings. The components of the system would be fabricated by a combination of (1) three-dimensional xray lithography and (2) highly precise injection molding of diamond-compatible metals and ceramic materials. The materials and fabrication techniques would be suitable for mass production. The disadvantages of the proposed system are that unlike a battery-based system, it could generate a perceptible amount of sound, and, if it were to burn fuel, then it would also generate exhaust, similarly to other combustion-based power sources.
The advantages are discussed of hydrostatic, high pressure bearings as providers of higher margin of stability to the rotor/bearing systems. It is apparent that deliberate use of hydrostatic bearing high pressure lubricated (any gas or liquid) can easily be used to build higher stability margin into rotating machinery, in spite of the thirty years bias against high pressure lubrication. Since this supply pressure is controllable (the Direct Dynamic Stiffness at lower eccentricity is also controllable) so that within some rotor system limits, the stability margin and dynamic response of the rotor system is more readily controllable. It may be possible to take advantage of this effect in the various seals, as well as the bearings, to assist with stability margin and dynamic response of rotating machinery. The stability of the bearing can be additionally improved by taking advantage of the anti-swirling concept. The high pressure fluid supply inlets should be located tangentially at the bearing circumference and directed against rotation. The incoming fluid flow creates stability by reducing the swirling rate.
An analytical study was performed in order to assess relative performance and economic factors involved with alternative advanced fuel systems for future commercial aircraft operating with broad property fuels. Significant results, with emphasis on design practicality from the engine manufacturer' standpoint, are highlighted. Several advanced fuel systems were modeled to determine as accurately as possible the relative merits of each system from the standpoint of compatibility with broad property fuel. Freezing point, thermal stability, and lubricity were key property issues. A computer model was formulated to determine the investment incentive for each system. Results are given.
Materials for potassium lubricated journal bearing and shaft applications in space system turbogenerators
Energy-efficient linear magnetic bearing maintains a precise small separation between its moving and stationary parts. Originally designed for cryogenic compressors on spacecraft, proposed magnetic bearing offers an alternative to roller or gas bearing in linear motion system. Linear noncontacting bearing operates in environments where lubricants cannot be used.
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.
The Oil-Free Turbomachinery Program at the NASA Glenn Research center is committed to, revolutionary improvements in performance, efficiency and reliability of turbomachinery propulsion systems. One of the key breakthroughs by which this goal is being achieved is the maturation of air lubricated foil bearing technology. Through experimental testing, foil bearings have demonstrated a variety of exceptional qualities that show them to have an important role in the future of rotordynamic lubrication. Most of the work done with foil bearings thus far has considered ambient air at atmospheric pressure as the working fluid or lubricating fluid in the bearing. However, special applications of oil-free technology require the use of air at non- standard ambient conditions or completely different working fluids altogether. The NASA Jupiter Icy Moon Orbiter program presents power generation needs far beyond that of any previous space exploration effort. The proposed spacecraft will require significant power generation to provide the propulsion necessary to reach the moons of Jupiter and navigate between them. Once there, extensive scientific research will be conducted that will also present significant power requirements. Such extreme needs require exploring a new method for power generation in space. A proposed solution involves a Brayton cycle nuclear fission reactor. The nature of this application requires reliable performance of all reactor components for many years of operation under demanding conditions. This includes the bearings which will be operating with an alternative working fluid that is a combination of Helium and Xenon gases commonly known as HeXe. This fluid has transport and thermal properties that vary significantly from that of air and the effect of these property differences on bearing performance must be considered. One of the most promising applications of oil-free technology is in aircraft turbine engines. Eliminating the oil supply systems from aircraft engines will lead to significant weight and maintenance reduction. In such applications, the lubricating fluid will be high altitude air. This air will be at much lower pressure than that at sea level. Again this property change will result in a change in bearing performance, and analysis is required to quantify this effect. The study of these alternate working fluid properties will be conducted in two ways: analytically and experimentally. Analytical research will include the use of a mathematical code that can predict film thickness profiles for various ambient conditions. Estimations of load capacity can be made based upon the film thickness trends. These values will then be compared to those obtained from classical rigid bearing analysis. Experimental Research will include testing a foil bearing at a variety of ambient air pressures. The analytical and experimental data will be compared to draw conclusions on bearing performance under alternate working fluid properties.
Description of the design and testing of a recuperated, closed Brayton-cycle, electrical power conversion system designated the Brayton Cycle Demonstrator (BCD). The system uses electrical heaters as a heat source, argon as the cycle working fluid, and gas-lubricated foil-type bearings. Objectives of the test program include (1) evaluation of the overall system performance characteristics and influences on spacecraft integration, (2) familiarization of personnel with operational methods, and (3) determination of system flexibility by operating at a number of off-design conditions. Results obtained to date are discussed.
The NASA Glenn Research Center has developed a patented high-temperature solid lubricant coating, designated PS304, for reducing friction and wear in bearing systems. The material used to produce the coating is initially a blend of metallic and ceramic powders that are deposited on the bearing surface by the plasma spray process. PS304 was developed to lubricate foil air bearings in Oil-Free turbomachinery, where the moving surfaces are coated with a hydrodynamic air film except at the beginning and end of an operation cycle when the air film is not present. The coating has been successful in several applications including turbochargers, land-based turbines, and industrial drying furnace conveyor components, with current development activities directed at implementation in Oil-Free aeropropulsion engines.
Several NASA missions suffered failures and anomalies due to problems in applying space mechanisms technology to specific projects. Research shows that engineers often lack either adequate knowledge of mechanism design or sufficient understanding of how mechanisms affect sensitive systems. The Space Mechanisms Project conducted a Lessons Learned study and published a Space Mechanisms Handbook to help space industry engineers avoid recurring design, qualification, and application problems. The Space Mechanisms Handbook written at the NASA Glenn Research Center details the state-of-the-art in space mechanisms design as of 1998. NASA's objective in developing this Space Mechanisms Handbook was to provide readily accessible information on such areas as space mechanisms design, mechanical component availability and use, testing and qualification of mechanical systems, and a listing of worldwide space mechanisms experts and testing facilities in the United States. This handbook has been expanded into a two-volume CD-ROM set in an Adobe Acrobat format. In addition to the handbook, the CD's include (1) the two volume Space Mechanisms Lessons Learned Study, (2) proceedings from all the NASA hosted Aerospace Mechanisms Symposia held through the year 2000, (3) the Space Materials Handbook, (4) the Lubrication Handbook for the Space Industry, (5) the Structural & Mechanical Systems Long-Life Assurance Design Guidelines, (6) the Space Environments and Effects Source-Book, (7) the Spacecraft Deployable Appendages manual, (8) the Fastener Design Manual, (9) A Manual for Pyrotechnic Design, Development and Qualification, (10) the Report on Alternative Devices to Pyrotechnics on Spacecraft, and (11) Gearing (a manual). In addition, numerous other papers on tribology and lubrication are included.This technical summary of the project provides information on how to obtain the handbook and related information.
In a marriage of research and commercial technology, a 30-kW Oil-Free Capstone microturbine electrical generator unit has been installed and is serving as a test bed for long-term life-cycle testing of NASA-developed PS304 shaft coatings. The coatings are used to reduce friction and wear of the turbine engine s foil air bearings during startup and shut down when sliding occurs, prior to the formation of a lubricating air film. This testing supports NASA Glenn Research Center s effort to develop Oil-Free gas turbine aircraft propulsion systems, which will employ advanced foil air bearings and NASA s PS304 high temperature solid lubricant to replace the ball bearings and lubricating oil found in conventional engines. Glenn s Oil-Free Turbomachinery team s current project is the demonstration of an Oil-Free business jet engine. In anticipation of future flight certification of Oil-Free aircraft engines, long-term endurance and durability tests are being conducted in a relevant gas turbine environment using the Capstone microturbine engine. By operating the engine now, valuable performance data for PS304 shaft coatings and for industry s foil air bearings are being accumulated.
The goal of this study is to provide technological support to ensure successful life and operation of a 50-300 kW dynamic power conversion system specifically with response to the rotor support system. By utilizing technical expertise in tribology, bearings, rotordynamic, solid lubricant coatings and extensive test facilities, valuable input for mission success is provided. A discussion of the history of closed cycle Brayton turboalternators (TA) will be included. This includes the 2 kW Mini-Brayton Rotating Unit (Mini-BRU), the 10kW Brayton Rotating Unit (BRU) and the 125 kW turboalternator-compressor (TAC) designed in mid 1970's. Also included is the development of air-cycle machines and terrestrial oil-free gas turbine power systems in the form of microturbines, specifically Capstone microturbines. A short discussion of the self-acting compliant surface hydrodynamic fluid film bearings, or foil bearings, will follow, including a short history of the load capacity advances, the NASA coatings advancements as well as design model advances. Successes in terrestrial based machines will be noted and NASA tribology and bearing research test facilities will be described. Finally, implementation of a four step integration process will be included in the discussion.
An analytical study was performed in order to assess relative performance and economic factors involved with alternative advanced fuel systems for future commercial aircraft operating with broadened property fuels. The DC-10-30 wide-body tri-jet aircraft and the CF6-8OX engine were used as a baseline design for the study. Three advanced systems were considered and were specifically aimed at addressing freezing point, thermal stability and lubricity fuel properties. Actual DC-10-30 routes and flight profiles were simulated by computer modeling and resulted in prediction of aircraft and engine fuel system temperatures during a nominal flight and during statistical one-day-per-year cold and hot flights. Emergency conditions were also evaluated. Fuel consumption and weight and power extraction results were obtained. An economic analysis was performed for new aircraft and systems. Advanced system means for fuel tank heating included fuel recirculation loops using engine lube heat and generator heat. Environmental control system bleed air heat was used for tank heating in a water recirculation loop. The results showed that fundamentally all of the three advanced systems are feasible but vary in their degree of compatibility with broadened-property fuel.
Following the establishment of the overall transport concept, a study of all of the life limiting constraints associated with the transport were analyzed using modeling techniques. These design techniques included: (1) a response analysis from which the performance of the transport could be determined under operating conditions for a variety of conceptual variations both in a new and aged condition; (2) an analysis of a double cone guidance technique which yielded an optimum design for maximum guidance with minimum tape degradation; (3) an analysis of the tape pack design to eliminate spoking caused by negative tangential stress within the pack; (4) an evaluation of the stress levels experienced by the magnetic tape throughout the system; (5) a general review of the bearing and lubrication technology as applied to satellite recorders and hence the recommendation for using standard load carrying antifriction ball bearings; and (6) a kinetic analysis to determine the change in kinetic properties of the transport during operation.
An evaluation is made of the state-of-the-art and foreseeable development prospects in high temperature engineering materials applicable to advanced heat engines and other aerothermodynamically affected structures. Attention is given to monocrystal- and microcrystal-producing metal solidification processes, soft oxide and chemically stable fluoride high temperature solid lubricants, polyimide and other high temperature polymers for propulsion system applications, high strength/toughness ceramics for heat engine structural components, thermal barrier coatings, and metal-matrix composites employing refractory matrices as well as reinforcing fibers.
Advanced flywheels utilizing high strength fibers must operate at high rotational speeds and as such must operate in vacuum to reduce windage losses. The utilization of magnetic bearings in the flywheels overcome lubrication and seal problems, resulting in an energy storage system offering potential improvements over conventional electrochemical energy storage. Magnetic bearings evolved in the 1950s from the simple application of permanent magnets positioned to exert repulsive forces to the present where permanent magnets and electromagnets have been combined to provide axial and radial suspension. Further development of magnetic suspension has led to the design of a shaftless flywheel system for aerospace application. Despite the lack of proof of concept, integrated magnetic suspension in inertial storage systems can provide significant performance improvements to warrant development and tests.
Future NASA long duration missions will require high performance, reliable, long lived mechanical moving systems. In order to develop these systems, high technology components, such as bearings, gears, seals, lubricants, etc., will need to be utilized. There has been concern in the NASA community that the current technology level in these mechanical component/tribology areas may not be adequate to meet the goals of long duration NASA mission such as Space Exploration Initiative (SEI). To resolve this concern, NASA-Lewis sent a questionnaire to government and industry workers (who have been involved in space mechanism research, design, and implementation) to ask their opinion if the current space mechanisms technology (mechanical components/tribology) is adequate to meet future NASA Mission needs and goals. In addition, a working group consisting of members from each NASA Center, DoD, and DOE was established to study the technology status. The results of the survey and conclusions of the working group are summarized.