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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 307 records · Page 17
All sourcesNASA NTRSDOE OSTI
NASA NTRS1980

Simplified fatigue life analysis for traction drive contacts

A simplified fatigue life analysis for traction drive contacts of arbitrary geometry is presented. The analysis is based on the Lundberg-Palmgren theory used for rolling-element bearings. The effects of torque, element size, speed, contact ellipse ratio, and the influence of traction coefficient are shown. The analysis shows that within the limits of the available traction coefficient, traction contacts exhibit longest life at high speeds. Multiple, load-sharing roller arrangements have an advantageous effect on system life, torque capacity, power-to-weight ratio and size.

Rohn, D. A.↗
DOE OSTI2015

COHESION OF AMORPHOUS SILICA SPHERES: TOWARD A BETTER UNDERSTANDING OF THE COAGULATION GROWTH OF SILICATE DUST AGGREGATES

Adhesion forces between submicrometer-sized silicate grains play a crucial role in the formation of silicate dust agglomerates, rocky planetesimals, and terrestrial planets. The surface energy of silicate dust particles is the key to their adhesion and rolling forces in a theoretical model based on contact mechanics. Here we revisit the cohesion of amorphous silica spheres by compiling available data on the surface energy for hydrophilic amorphous silica in various circumstances. It turned out that the surface energy for hydrophilic amorphous silica in a vacuum is a factor of 10 higher than previously assumed. Therefore, the previous theoretical models underestimated the critical velocity for the sticking of amorphous silica spheres, as well as the rolling friction forces between them. With the most plausible value of the surface energy for amorphous silica spheres, theoretical models based on the contact mechanics are in harmony with laboratory experiments. Consequently, we conclude that silicate grains with a radius of 0.1 μm could grow to planetesimals via coagulation in a protoplanetary disk. We argue that the coagulation growth of silicate grains in a molecular cloud is advanced either by organic mantles rather than icy mantles or, if there are no mantles, by nanometer-sized grain radius.

79 ASTRONOMY AND ASTROPHYSICS↗
NASA NTRS1983

Predicted and experimental performance of large-bore high-speed ball and roller bearings

The values of inner and outer race temperature, cage speed, and heat transferred to the lubricant or bearing power loss, calculated using the computer programs Shaberth and Cybean, with the corresponding experimental data for the large bore ball and roller bearings were compared. After the development of computer program, it is important that values calculated using such program are compared with actual bearing performance data to assess the programs predictive capability. Several comprehensive computer programs currently in use are capable of predicting rolling bearing operating and performance characteristics. These programs accept input data of bearing internal geometry, bearing material and lubricant properties, and bearing operating conditions. The programs solve several sets of equations that characterize rolling element bearings. The output produced typically consists of rolling element loads and Hertz stresses, operating contact angles, component speed, heat generation, local temperatures, bearing fatigue life, and power loss. Two of these programs, Shaberth and Cybean were developed.

Coe, H. H.↗
NASA NTRS1993

Computer program for analysis of high speed, single row, angular contact, spherical roller bearing, SASHBEAN. Volume 1: User's guide

The computer program SASHBEAN (Sikorsky Aircraft Spherical Roller High Speed Bearing Analysis) analyzes and predicts the operating characteristics of a Single Row, Angular Contact, Spherical Roller Bearing (SRACSRB). The program runs on an IBM or IBM compatible personal computer, and for a given set of input data analyzes the bearing design for it's ring deflections (axial and radial), roller deflections, contact areas and stresses, induced axial thrust, rolling element and cage rotation speeds, lubrication parameters, fatigue lives, and amount of heat generated in the bearing. The dynamic loading of rollers due to centrifugal forces and gyroscopic moments, which becomes quite significant at high speeds, is fully considered in this analysis. For a known application and it's parameters, the program is also capable of performing steady-state and time-transient thermal analyses of the bearing system. The steady-state analysis capability allows the user to estimate the expected steady-state temperature map in and around the bearing under normal operating conditions. On the other hand, the transient analysis feature provides the user a means to simulate the 'lost lubricant' condition and predict a time-temperature history of various critical points in the system. The bearing's 'time-to-failure' estimate may also be made from this (transient) analysis by considering the bearing as failed when a certain temperature limit is reached in the bearing components. The program is fully interactive and allows the user to get started and access most of its features with a minimal of training. For the most part, the program is menu driven, and adequate help messages were provided to guide a new user through various menu options and data input screens. All input data, both for mechanical and thermal analyses, are read through graphical input screens, thereby eliminating any need of a separate text editor/word processor to edit/create data files. Provision is also available to select and view the contents of output files on the monitor screen if no paper printouts are required. A separate volume (Volume-2) of this documentation describes, in detail, the underlying mathematical formulations, assumptions, and solution algorithms of this program.

Aggarwal, Arun K.↗
NASA NTRS1973

Study of ball bearing torque under elastohydrodynamic lubrication

Spinning and rolling torques were measured in an angular-contact ball bearing with and without a cage under several lubrication regimes in a modified NASA spinning torque apparatus. Two lubricants were used, a di-2 ethylhexyl sebacate and a synthetic paraffinic oil, at shaft speeds of 1000, 2000, and 3000 rpm and bearing loads from 10 lbs to 90 lbs. An analytical model was developed from previous spinning friction models to include rolling with spinning under lubrication regimes from thin film to flooded conditions. The bearing torque values have a wide variation, under any condition of speed and load, depending on the amount of lubricant present in the bearing. The analytical model compared favorably with experimental results under several lubrication regimes.

Townsend, D. P.↗
NASA NTRS1973

Study of ball bearing torque under elastohydrodynamic lubrication

Spinning and rolling torques were measured in an angular-contact ball bearing with and without a cage under several lubrication regimes in a modified NASA spinning torque apparatus. Two lubricants were used - a di-2 ethylhexyl sebacate and a synthetic paraffinic oil, at shaft speeds of 1000, 2000, and 3000 rpm and bearing loads from 45 newtons (10 lb) to 403 newtons (90 lb). An analytical model was developed from previous spinning friction models to include rolling with spinning under lubrication regimes from thin film to flooded conditions. The bearing torque values have a wide variation, under any condition of speed and load, depending on the amount of lubricant present in the bearing. The analytical model compared favorably with experimental results under several lubrication regimes.

Townsend, D. P.↗
NASA NTRS1987

Heat generation in Aircraft tires under yawed rolling conditions

An analytical model was developed for approximating the internal temperature distribution in an aircraft tire operating under conditions of yawed rolling. The model employs an assembly of elements to represent the tire cross section and treats the heat generated within the tire as a function of the change in strain energy associated with predicted tire flexure. Special contact scrubbing terms are superimposed on the symmetrical free rolling model to account for the slip during yawed rolling. An extensive experimental program was conducted to verify temperatures predicted from the analytical model. Data from this program were compared with calculation over a range of operating conditions, namely, vertical deflection, inflation pressure, yaw angle, and direction of yaw. Generally the analytical model predicted overall trends well and correlated reasonably well with individual measurements at locations throughout the cross section.

Dodge, Richard N.↗
DOE OSTI2022

Alternate Methods for Cleaning Zirconium Plate

The United States High Performance Research Reactor Conversion Program identified the need to transition from highly enriched uranium fuel to lowly enriched uranium fuel for high power research and civil reactors. One of the fuel configurations selected for these reactors was a uranium (U) foil alloyed with 10% molybdenum (Mo). The U-10Mo fuel foil was then covered with a zirconium (Zr) interlayer and pressed into an aluminum cladding. Idaho National Laboratory prescribed a need to remove surface oxidation on the Zr prior to bonding it with U-10Mo fuel foil. To determine the best method of oxidation removal, a variety of polishing methods, including hand polishing with a diamond paste or Scotch-Brite™ pads, mechanically wet-polishing with abrasive belts, and chemical etching with hydrofluoric/nitric acid mixtures, were investigated on pre-polished Zircaloy 702 sheets purchased directly from the manufacturer. No change in surface roughness was detected using any of these methods relative to the as-received material. In fact, scanning electron microscopy detected grit from hand polishing with Amplex Grade 30 waste soluble diamond paste and Scotch-Brite™ pads. Visible staining was found, and fluorine detected via X-ray photoelectron spectroscopy on the flash etching samples. These contaminants were not seen on the as-received material. In addition to the need to remove the oxide layer on the Zr prior to co-rolling, there are concerns that the Neolube debonding agent on the co-rolling can may contaminate the Zr surface after co-rolling. The experimental results found that zirconium in contact with Neolube coated steel plates was easily cleaning with ethanol wiping after heat treated and no carbide inclusions remained on the surface. Overall, all cleaning methods tested did not significantly change the surface roughness of the plates or reduce the oxide layer present on the zirconium. Carbon was found on all the samples, before and after cleaning, except for the flash etch samples which detected fluorine instead. The insignificant changes seen in the cleaned plates relative to the as received plates question the need for cleaning prior to rolling. Further investigation in the requirements for cleaning at this step is recommended. Current methods for cleaning the surface after hot rolling with alcohol appear sufficient. After hot rolling, if Neolube does peel off the can and onto the zirconium coated foil surface, a dry abrasive or diamond paste polish is not recommended due to the chance of abrasive being embedded into the surface. However, the ability of an etchant to lift the lubricant off the zirconium surface indicates that a spot etch method could work to clean specific spots where Neolube is present, if the need arises.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS1996

Three-dimensional roller locking sprags

A torque coupling sprag system which provides contact between the sides of at least one groove and at least two contact surfaces angled with respect to the central axial direction of at least one rotatable 3-D sprag member located between a drive member and a reaction member. The surface contacts between the members include various combinations of surface segments arranged in a predetermined manner to define a desired configuration. The contact radius of the 3-D sprag member is significantly larger than its rolling radius; however, radii can be varied in size and shape independently of each other, particularly the contact radius.

Vranish, John M.↗
NASA NTRS1980

Surface temperatures and glassy state investigations in tribology

Measurements were made of the limiting shear stress for two naphthenic oils of differing molecular weight and three blends of the lower molecular weight oil and polymers of differing molecular weight. All reached the same limiting shear stress for the same temperature and pressure; although the polymer solutions reduced the limiting shear stress by about fifteen percent. A falling body viscometer was constructed to operate to 230 C and to 0.6 GPa and another was constructed to extend the pressure range to 1.1 GPa. A concentrated contact simulator was developed which allows recording of the traction force while the slide-roll ratio is continuously varied and the rolling speed is maintained essentially constant. Measurement of lubricant minimum film thickness of elliptical EHD contacts of various aspect ratios were made by optical interferometry. The experimental data were thirty percent greater than that predicted by the Hamrock and Dowson model. Preliminary development of the application of a scanning infrared radiation system to a tribological system was completed.

Bair, S.↗
NASA NTRS2004

High-Temperature Hybrid Rotor Support System Developed

The Army Research Laboratory Vehicle Technology Directorate and the NASA Glenn Research Center demonstrated a unique high-speed, high-temperature rotor support system in September 2003. Advanced turbomachinery is on its way to surpassing the capabilities of rolling-element bearings and conventional dampers. To meet these demands, gas turbine engines of the future will demand increased efficiency and thrust-to-weight ratio, and reduced specific fuel consumption and noise. The more-electric engine replaces oil-lubricated bearings, dampers, gears, and seals with electrical devices. One such device is the magnetic bearing. The Vehicle Technology Directorate and Glenn have demonstrated the operation of a radial magnetic bearing in combination with a hydrostatic bearing at 1000 F at 31,000 rpm (2.3 MDN1). This unique combination takes advantage of a high-temperature rub surface in the event of electrical power loss or sudden overloads. The hydrostatic bearings allow load sharing with the magnetic bearing. The magnetic-hydrostatic bearing combination eliminates wear and high contact stress from sudden acceleration of the rolling-element bearings and overheating. The magnetic bearing enables high damping, adaptive vibration control, and precise rotor positioning, diagnostics, and health monitoring. A model of the test facility used at Glenn for this technology demonstration is shown. A high-temperature heteropolar radial magnetic bearing is located at the center of gravity of the test rotor. There is a 0.022-in. radial air gap between the rotor and stator. Two rub surface hydrostatic bearings were placed on either side of the magnetic bearing. The rotor is supported by a 0.002-in. hydrostatic air film and the magnetic field. The prototype active magnetic bearing cost $24,000 to design and fabricate and a set of four high temperature, rub-surface, hydrostatic bearings cost $28,000. This work was funded by the Turbine-Based Combined Cycle program.

Montague, Gerald T.↗
DOE OSTI2018

Interaction Between Graphene-Coated SiC Single Crystal and Liquid Copper

The wettability of graphene-coated SiC single crystal (C{sub Gn}/SiC{sup sc}) by liquid Cu (99.99%) was investigated by a sessile drop method in vacuum conditions at temperature of 1100 °C. The graphene layer was produced via a chemical vapor deposition routine using 4H-SiC single crystal cut out from 6″ wafer. A dispensed drop technique combined with a non-contact heating of a couple of materials was applied. The Cu drop was squeezed from a graphite capillary and deposited on the substrate directly in a vacuum chamber. The first Cu drop did not wet the C{sub Gn}/SiC{sup sc} substrate and showed a lack of adhesion to the substrate: the falling Cu drop only touched the substrate forming a contact angle of θ{sub 0} = 121° and then immediately rolled like a ball along the substrate surface. After settling near the edge of the substrate in about 0.15 s, the Cu drop formed an asymmetric shape with the right and left contact angles of different values (θ{sub R} = 86° and θ{sub L} = 70°, respectively), while in the next 30 min, θ{sub R} and θ{sub L} achieved the same final value of ~ 52°. The second Cu drop was put down on the displacement path of the first drop, and immediately after the deposition, it also did not wet the substrate (θ = 123°). This drop kept symmetry and the primary position, but its wetting behavior was unusual: both θ{sub R} and θ{sub L} decreased in 17 min to the value of 23° and next, they increased to a final value of 65°. Visual observations revealed a presence of ~ 2.5-mm-thick interfacial phase layer reactively formed under the second drop. Scanning electron microscopy (SEM) investigations revealed the presence of carbon-enriched precipitates on the top surface of the first Cu drop. These precipitates were identified by the Raman spectroscopy as double-layer graphene. The Raman spectrum taken from the substrate far from the drop revealed the presence of graphene, while that obtained from the first drop displacement path exhibited a decreased intensity of 2D peak. The results of SEM investigations and Raman spectroscopy studies suggest that the presence of graphene layer on the SiC substrate suppresses but does not completely prevent chemical interaction between liquid Cu drop and SiC. Both chemical degradation (etching) and mechanical degradation of the graphene layer during drop rolling due to high adhesion of the Cu drop to the SiC substrate are responsible for mass transfer through the 2nd drop/substrate interface that in turn results in significant changes of structure and chemistry of the drop and the interface.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
NASA NTRS2022

Analysis of Base Metal Microstructures and Mechanical Properties of a Single-Piece, Spin-Formed Forward Pressure Vessel Bulkhead

In 2012, a pathfinder forward pressure vessel bulkhead (FPVBH) for the Orion Multi-Purpose Crew Vehicle (MPCV) was fabricated using aluminum (Al) alloy 2219. The demonstration article was offered as a replacement for the baseline configuration, which at that time was a multi-piece welded construction using aluminum-lithium (Al-Li) alloy 2195. In 2014, the NASA Engineering and Safety Center (NESC) funded a Phase I effort to explore spin-forming as a manufacturing method to produce a complex-shaped, single-piece FPVBH for the crew module (CM) [1]. The primary focus of the NESC effort was to expand spin-forming technology to the fabrication of an Al-Li 2195 FPVBH. As a result, limited testing and analysis was performed on the original Al 2219 article. In this study, a sufficiently large plate of Al 2219 was not available for the fabrication of a FPVBH. Therefore, the forming blank comprised two plates (from different lots) butt welded together using a single friction stir weld. The welded forming blank was then spin formed into the FPVBH configuration and heat treated to the T62 temper. Mechanical property testing of the spin-formed 2219-T62 FPVBH revealed that the tensile properties were comparable to the Metallic Material Properties Development and Standardization (MMPDS) A-basis allowable for Al 2219-T6 wrought products. However, post-spin forming application of the standard heat treatment produced large, recrystallized grains in the material. The response varied within the two plates; one plate lot exhibited nearly complete recrystallization, while the other lot contained bands of recrystallization. Although no reduction in tensile properties was observed due to these microstructural variations, a more detailed investigation was recommended to better understand the effect of spin forming on the recrystallization mechanism and the impact on other material properties. The current study examined the microstructure and mechanical properties of the fully processed Al 2219-T62 FPVBH with emphasis on comparing differences between the two plates. Testing was limited to the cone region of the FPVBH. The two specific tasks in this study were: a) Characterization of the microstructure and mechanical properties in the two plates used in the FPVBH. b) Isolation of the impact of each step in the thermo-mechanical processing (TMP) sequence of the FPVBH on recrystallization and grain growth. Mechanical property testing sampled regions containing both large, recrystallized and small, unrecrystallized grains. Tensile strengths and elongations were equivalent in both regions and exceeded MMPDS A-basis allowables. Fracture toughness was equivalent in both regions and fracture morphology was typical of aluminum alloys. The fatigue precrack region of the fracture toughness specimens appeared more faceted in the recrystallized plate. This suggests that property testing that is more sensitive to grain size, such as fatigue crack growth rate and stress corrosion cracking, may be warranted. Alcoa reviewed the production records for the two plate lots and confirmed that composition of both plates was within the allowable range for Al 2219 and that plate processing steps were all performed within production limits. However, the Fe content was notably higher in the fully recrystallized plate, resulting in a greater volume fraction of large Fe-bearing inclusions and Al-Cu constituent particles. Alcoa did not provide details regarding plate processing variables for the two plate lots. It was surmised that deformation by hot rolling was the most accurate TMP simulation of commercial spin forming within a laboratory setting. Both hot rolling and spin forming comprise combinations of shear and compressive deformation. The through-thickness strain caused by hot rolling is symmetrical about the mid-plane, as the rollers contact both sides of the material. Shear strains are maximum at the inner and outer surfaces and trend toward zero at the mid-thickness. In contrast, spin forming utilizes a single roller on the outer surface, producing a gradient in shear stress through the thickness. Shear strains in spin-formed material are highest at the outer surface due to direct contact with the roller, and trend toward zero at the inner surface. Consequently, there will undoubtedly be some discrepancies in the mechanical response of hot-rolled and spin-formed products in the through-thickness direction. Interrupted TMP simulations were performed on remnant plate from the FPVBH forming blank in order to isolate the effects of a post-weld anneal, spin-forming deformation/thermal cycling, and solution heat treatment (SHT) on development of the recrystallized microstructures. Analysis confirmed that large, recrystallized grains formed exclusively during SHT and only after a certain deformation level was exceeded. Remnant plate from both lots that received thermal processing only did not exhibit recrystallization but exhibited fully recrystallized microstructures when processed by hot rolling. This indicates that (1) the level of deformation exceeded the critical level for recrystallization in both plates and (2) that the level of deformation during hot rolling was greater than that which accumulated during spin forming of the FPVBH. Comparison of the hot-rolled plate with the spin-formed material showed that the recrystallized grain size was larger in the FPVBH, providing further evidence that deformation levels were lower in the FPVBH. The most plausible explanation for the differing degrees of recrystallization in the two plates is particle stimulated nucleation (PSN) at the Fe-bearing inclusions and large Al-Cu constituent particles. In the plate with higher solute content, the greater volume fraction of these particles reduces the deformation level required to promote recrystallization. During spin forming the critical deformation level was likely exceeded for the higher Fe content plate resulting in a fully recrystallized microstructure. The lower Fe content plate developed a microstructure that exhibited bands of recrystallization due to the combination of a non-uniform distribution of particles and deformation. The critical deformation required for recrystallization was likely only exceeded during spin forming in regions of higher particle content. While there were differences in Fe content between these lots of Al 2219 plate, the composition of both was within defined alloy limits and Alcoa reported no anomalies during plate production. The observed differences in recrystallization after spin forming may reflect the inherent variability between these two lots of plate. The spin-forming vendor, Spincraft, reported that similar variations in recrystallized microstructures have been observed during examination of multiple spin-forming trials of a different 2xxx series aluminum alloy. Hence, tighter chemical specification limits on impurity levels in Al 2219 plate may help ensure uniform, predictable microstructures. Finally, the tensile and fracture toughness properties were not affected by the microstructural variations noted.

single-piece↗
NASA NTRS1974

Cibachrome testing

The use of Cibachrome products as a solution to problems encountered when contact printing Kodak film type SO-397 onto Kodak Ektrachrome color reversal paper type 1993 is investigated. A roll of aerial imagery consisting of Kodak film types SO-397 and 2443 was contact printed onto Cibachrome and Kodak materials and compared in terms of color quality, resolution, cost, and compatibility with existing equipment and techniques. Objective measurements are given in terms of resolution and sensitometric response. Comparison prints and transparencies were viewed and ranked according to overall quality and aesthetic appeal. It is recommended that Cibachrome Print material be used in place of Kodak Ektachrome paper because it is more easily processed, the cost is equivalent, and it provides improved resolution, color quality, and image fade resistance.

Weinstein, M. S.↗
NASA NTRS1981

Simplified solution for stresses and deformations

A shortcut is presented to the classical Hertzian solution for local stress and deformation of two elastic bodies in contact, which employs simplified forms for the ellipticity and for the complete elliptic integrals of the first and second kinds as a function of the geometry. Unlike previously proposed simplified formulas whose range of applicability was limited to ellipticities equal to, or greater than one, the present method extends the range of validity to include ellipticities less than one; in which the semimajor axis in the elliptical contact lies in a direction parallel to the rolling, rather than being perpendicular, as in previous studies. An auxiliary shear stress parameter is also expressed in simplified form as a function of the geometry, permitting a shortcut calculation to be made for the location and magnitude of the maximum subsurface shear stress.

Hamrock, B. J.↗
NASA NTRS1975

Effect of starvation on film thickness and traction under elastohydrodynamic rolling and sliding conditions

Traction measurements under starved elastohydrodynamic conditions were obtained for a point-contact geometry. Simultaneous measurements of the film thickness and the location of the inlet lubricant boundary were made. Optical interferometry was used to measure film thickness. The thickness of a starved film for combined rolling and sliding conditions varies with the location of the inlet boundary in the same way as previously found for pure rolling conditions. When the fluid velocity distribution is calculated in the inlet region by a Reynolds lubrication analysis, backflow is seen to occur over a portion of the inlet region. Backflow is essential for the establishment of a flooded condition. The location of certain fluid velocity conditions within the inlet region, as suggested in the literature, does not adequately describe the onset of starvation. For the same slide-roll ratio a starved film was observed to possess greater traction than a flooded film. Traction measurements under starved conditions were also compared with those under flooded conditions for equivalent shear rates in the Hertzian region. When the shear rates within the Hertzian region were low and the film was severely starved, the measured tractions were lower than expected. This may be due to large shear stresses developed by the large pressure gradients that are generated in the inlet region when it is severely starved.

Wedeven, L. D.↗
NASA NTRS1991

Local Synthesis and Tooth Contact Analysis of Face-Milled Spiral Bevel Gears

Computerized simulation of meshing and bearing contact for spiral bevel gears and hypoid gears is a significant achievement that could substantially improve the technology and the quality of the gears. An approach to the synthesis of face-milled spiral bevel gears and their tooth contact analysis is presented. The proposed approach is based on the following ideas: application of the principle of local synthesis that provides optimal conditions of meshing and contact at the mean contact point, M, and in the neighborhood of M; and application of relations between principle directions and curvatures for surfaces being in line contact or in point contact. The developed local synthesis of gears provides the following: (1) the required gear ratio at M; (2) a localized bearing contact with the desired direction of the tangent to the contact path on gear tooth surface and the desired length of the major axis of contact ellipse at M; (3) a predesigned parabolic function of a controlled level for transmission errors which enables absorption of linear functions of transmission errors caused by misalignment and reduces the level of vibrations. The proposed approach does not require either the tilt of the head-cutter for the process of generation or modified roll for the pinion generation. Improved conditions of meshing and contact of the gears can be achieved without the above mentioned parameters. A computer program for determination of basic machine-tool settings and tooth contact analysis for the designed gears is presented. The approach is illustrated with a numerical example.

Litvin, Faydor L.↗