Search NASA⌕ Search

SEARCH · Search NASA

Results for “ROLLING CONTACT”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 307 records · Page 17

Heat treat fixture and method of heat treating

A heat treating fixture is disclosed in which the shape of the metal specimen is maintained by cold rolled steel support plates. Glide sheets of stainless steel, coated with boron nitride, in contact with each face of the metal specimens, allow for lateral expansion of the metal specimens without binding. Grooved support bars separate the glide sheets from the upper and lower support plates and allow flow of quenching fluid to the metal specimen.

Beuyukian, C. S.↗

Automated inspection and precision grinding of spiral bevel gears

The results are presented of a four phase MM&T program to define, develop, and evaluate an improved inspection system for spiral bevel gears. The improved method utilizes a multi-axis coordinate measuring machine which maps the working flank of the tooth and compares it to nominal reference values stored in the machine's computer. A unique feature of the system is that corrective grinding machine settings can be automatically calculated and printed out when necessary to correct an errant tooth profile. This new method eliminates most of the subjective decision making involved in the present method, which compares contact patterns obtained when the gear set is run under light load in a rolling test machine. It produces a higher quality gear with significant inspection time and cost savings.

Frint, Harold↗

Optimized Coolant-Flow Diverter For Increased Bearing Life

Coolant-flow diverter for rolling-element bearings in cryogenic turbopump designed to enhance cooling power of flow in contact with bearings and thereby reduce bearing wear. Delivers jets of coolant as close as possible to hot spots at points of contact between balls and race. Also imparts swirl that enhances beneficial pumping effect. Used with success in end ball bearing of high-pressure-oxidizer turbopump.

Subbaraman, Maria R.↗

Marshall Space Flight Center solid waste characterization and recycling improvement study: General office and laboratory waste, scrap metal, office and flight surplus

The primary objectives of the study were to characterize the solid waste stream for MSFC facilities in Huntsville, Alabama, and to evaluate their present recycling program. The purpose of the study was to determine if improvements could be made in terms of increasing quantities of the present commodities collected, adding more recyclables to the program, and streamlining or improving operational efficiency. In conducting the study, various elements were implemented. These included sampling and sorting representative samples of the waste stream; visually inspecting each refuse bin, recycle bin, and roll-off; interviewing employees and recycling coordinators of other companies; touring local material recycling facilities; contacting experts in the field; and performing a literature search.

Eley, Michael H.↗

The Mars Environmental Compatibility Assessment MECA Abrasion Tool

The Mars Environmental Compatibility Assessment (MECA) experiment, an instrument suite to be flown on Mars Surveyor 2001, will include a tool for doing simple mineralogical scratch and streak tests on particles from the Martian regolith. The Abrasion Tool will be applied to particles that adhere to highly polished substrates of various hardnesses. Granular soil components will be subjected to a compressive force of about 3 N using a leaf spring. The spring will be applied with a paraffin actuator capable of a 0.76 mm throw to achieve a maximum displacement of about 7.5 mm at the tip of the tool. The pressure per grain will be dependent on the grain size, the number of grains that adhere to the substrate and the number of grains in compression. The pressure per particle is expected to be on the order of 100 MPa - 1 GPa. The MECA sample wheel containing the substrates will be rotated after the particles are placed in compression to produce scratches or pits. A primary goal of the Abrasion Tool is to identify quartz (Mohs' hardness = 7) using substrates of varying hardnesses. Quartz is considered hazardous to future human explorers of Mars because it can cause silicosis of the lungs if it is of respirable size. It is also hazardous to machinery, structures, and space suits because of its ability to abrade and scratch surfaces. Since large quantities of minerals harder than quartz are not expected, any scratches produced on polished quartz substrates might be reasonably attributed to quartz particles, although there may be minerals such as impact metamorphic diamond in the soils. Careful calibration of the tool will be necessary to ensure that grains are not overloaded; for example, a steel ball pressed into glass will produce a Hertzian fracture, even though it is softer than glass. Other minerals, such as magnetite (Mohs'hardness = 6.5) have been shown to scratch glass ceramics such as Zerodur (Mohs' hardness = 6.5). Thus, minerals can be differentiated: note that regardless of the mineral species, if any particle is harder than 6.5 it will certainly be an interesting discovery for both planetary geology and human exploration concerns. The scratches will be identified using the 6X optical microscope and profiled with the atomic force microscope included in the MECA instrument suite. Analysis of the scratch morphology will yield evidence concerning the shape of the particle responsible for producing each scratch. For example, angular grains should leave vertical cracks with microconchoidal lateral chipping, while rounded grains might leave chattermarks, or nested partial Hertzian cracks. Particle shape can thus be inferred from these indentation modes, as well as material hardness. In addition, particle size information may also be available if pits caused by rolling particles can be identified. Converse to scratching, the minerals may be crushed at their contact points, and be smeared onto the target substrates to leave what geologists refer to as "streaks". These are coldwelded trails of mineral material that have structure and color indicative of mineral composition. The AFM will determine the morphology of these streaks, while the microscope will ascertain the color. On the harder substrates, we might expect streaking to dominate; on the softer substrates, scratching may dominate. Progressions of material interactions across the substrate selection will be a valuable source of data for mineral discrimination. It should also be noted that many minerals have coatings (such as iron oxides), and these will have to be differentiated from the host mineral grains; laboratory tests will establish the effects of such coatings on the scratch results. Finally, we note that the microscope will provide corroborative data regarding likely mineral species by grain shapes, fracture patterns, surface textures, colr, and UV fluorescence reactions.

Kuhlman, K. R.↗

The Mars Environmental Compatibility Assessment (MECA) Abrasion Tool

The Mars Environmental Compatibility Assessment (MECA) experiment, an instrument suite to be flown on Mars Surveyor 2001, will include a tool for doing simple mineralogical scratch and streak tests on particles from the Martian regolith. The Abrasion Tool will be applied to particles that adhere themselves to highly polished substrates of various hardnesses. Granular soil components will be subjected to a compressive force of about 3 N using a leaf spring. The spring will be applied with a paraffin actuator capable of a 0.76 mm throw to achieve a maximum displacement of about 7.5 mm at the tip of the tool. The pressure per grain will be dependent on the grain size, the number of grains that adhere to the substrate and the number of grains in compression. The pressure per particle is expected to be on the order of 100 MPa - 1 GPa. The MECA sample wheel containing the substrates will be rotated after the particles are placed in compression to produce scratches or pits. A primary goal of the Abrasion Tool is to identify quartz (Mohs' hardness = 7) using substrates of varying hardnesses. Quartz is considered hazardous to future human explorers of Mars because it can cause silicosis of the lungs if it is of respirable size. It is also hazardous to machinery, structures, and space suits because of its ability to abrade and scratch surfaces. Since large quantities of minerals harder than quartz are not expected, any scratches produced on polished quartz substrates might be reasonably attributed to quartz particles, although there may be minerals such as impact metamorphic diamond in the soils. Careful calibration of the tool will be necessary to ensure that grains are not overloaded; for example, a steel ball pressed into glass will produce a Hertzian fracture, even though it is softer than glass. Other minerals, such as magnetite (Mohs' hardness = 6.5) have been shown to scratch glass ceramics such as Zerodur (Mohs' hardness = 6.5). Thus, minerals can be differentiated: note that regardless of the mineral species, if any particle is harder than 6.5 it will certainly be an interesting discovery for both planetary geology and human exploration concerns. The scratches will be identified using the 6X optical microscope and profiled with the atomic force microscope included in the MECA instrument suite. Analysis of the scratch morphology will yield evidence concerning the shape of the particle responsible for producing each scratch. For example, angular grains should leave vertical cracks with microconchoidal lateral chipping, while rounded grains might leave chatter marks, or nested partial Hertzian cracks. Particle shape can thus be inferred from these indentation modes, as well as material hardness. In addition, particle size information may also be available if pits caused by rolling particles can be identified. Converse to scratching, the minerals may be crushed at their contact points, and be smeared onto the target substrates to leave what geologists refer to as "streaks". These are cold-welded trails of mineral material that have structure and color indicative of mineral composition. The AFM will determine the morphology of these streaks, while the microscope will ascertain the color. On the harder substrates, we might expect streaking to dominate; on the softer substrates, scratching may dominate. Progressions of material interactions across the substrate selection will be a valuable source of data for mineral discrimination. It should also be noted that many minerals have coatings (such as iron oxides), and these will have to be differentiated from the host mineral grains; laboratory tests will establish the effects of such coatings on the scratch results. Finally, we note that the microscope will provide corroborative data regarding likely mineral species by grain shapes, fracture patterns, surface textures, color, and UV fluorescence reactions. Additional information is contained in the original extended abstract.

Kuhlman, K. R.↗

Real-Time Modeling of Thermal Interactions in Cryogenic Ball Bearings

Based on the integration of classical differential equations of motion of bearing elements, a real-time dynamic simulation of ball bearing performance is coupled with simultaneous modeling of thermal interactions between the bearing elements. The transient heat generations are time averaged over a significantly larger time step before they are used to compute the changes in bearing temperature fields. Such an averaging algorithm eliminates the numerical difficulties associated with simultaneous integration of mechanical thermal differential equations with vastly different time scales. Under stable operation, the step change in temperatures at each thermal time step converges to a steady-state solution. Following is a list of accomplishments in the present investigation: (1) A real-time dynamic performance of both 440C and hybrid ball bearings in a LOX environment is modeled in both transient and steady-state time domains, as the inner race accelerates to a prescribed operating speed. (2) The frictional interactions at the ball to race contacts are modeled by experimentally measured traction coefficients as a function of slide-to-roll ratios. (3) Bearing heat generation, as defined by the heat transferred to circulating LOX, is validated against experimental values determined by measured LOX temperatures under prescribed pressures and flow rates. The predicted heat generation is in good agreement with the experimental values. (4) The steady-state solutions are shown to be independent of initial conditions. This establishes convergence of the numerical integration of a differential equation of motion of the bearing elements. (5) Churning and drag losses in the circulating LOX constitutes the majority of bearing heat generation under the experimental test conditions. (6) The heat dissipated in frictional interactions in hybrid bearings is significantly lower in hybrid bearings in comparison to that simulated in all-steel bearings, while the churning and drag losses are relatively unchanged.

Gupta, P. K.↗

Resilient and Corrosion-Proof Rolling Element Bearings Made from Superelastic Ni-Ti Alloys for Aerospace

Mechanical components (bearings, gears, mechanisms) typically utilize hardened construction materials to minimize wear and attain long life. In such components, loaded contact points (e.g., meshing gear teeth, bearing balls-raceway contacts) experience high contact stresses. The combination of high hardness and high elastic modulus often leads to damaging contact stress and denting, particularly during transient overload events such as shock impacts that occur during the launching of space vehicles or the landing of aircraft. In this webinar, Dr. DellaCorte will introduce the results of a research project that employs a superelastic alloy, Ni-Ti for rolling element bearing applications. Bearings and components made from such alloys can alleviate many problems encountered in advanced aerospace applications and may solve many terrestrial applications as well

intermetallics↗

Flexible, FEP-Teflon covered solar cell module development

Techniques and equipment were developed for the large scale, low-cost fabrication of lightweight, roll-up and fold-up, FEP-Teflon encapsulated solar cell modules. Modules were fabricated by interconnecting solderless single-crystal silicon solar cells and heat laminating them at approximately 300 C between layers of optically clear FEP and to a loadbearing Kapton substrate sheet. Modules were fabricated from both conventional and wraparound contact solar cells. A heat seal technique was developed for mechanically interconnecting modules into an array. The electrical interconnections for both roll-up and fold-up arrays were also developed. The use of parallel-gap resistance welding, ultrasonic bonding, and thermocompression bonding processes for attaching interconnects to solar cells were investigated. Parallel-gap welding was found to be best suited for interconnecting the solderless solar cells into modules. Details of the fabrication equipment, fabrication processes, module and interconnect designs, environmental test equipment, and test results are presented.

Rauschenbach, H. S.↗

Charging and Subsequent Dissipation of a Rover Wheel in the Lunar Polar Regions

As a roving vehicle moves along the lunar surface, electric charge will build up through tribo-charging. This charge collected by the roving object will have a dissipative path to either the surface or the ambient plasma, depending upon which path is most conductive. At the lunar terminator region and into nightside regions, the surface is very cold and becomes a very poor conductor. leaving the plasma as the dominant remediating current for dissipation. However, within lunar craters, even plasma currents become substantially reduced which then greatly increases electric 'dissipation times, This work will involve the advancement of the stepping astronaut charge model, by considering the charging and plasma dissipation of a rolling rover wheel, The objective of this work is to determine the nature of charging and discharging for a rover wheel as it rolls along the cold, plasma-starved lunar polar regions. The rotating wheel accumulates charge via contact electrification (tribo-charging) with the lunar regolith. This tribo-charging is dependent on the composition of the objects in contact, with insulators and conductors charging differently. Given the environmental plasma in the region, we then determine the dissipation time for the wheel to bleed off its excess charge into the surrounding plasma. A model of the rover wheel rotating continuously over a surface regolith within a polar crater has been applied. The environmental plasma has been described previously. We define a new tribo-charging term specifically for the rotating system, with charge levels defined as a function of the wheel size, area in contact with the regolith, regolith particle size distribution, as well as the velocity at which the wheel is turning. We recognize that as charged dust accumulates and sticks to the wheel, this behaves effectively as a new current. Hence, the overall charging of the system should no longer vary linearly. and begin to show signs of saturation, We are devising a dust current term to model this charge-limiting effect, and will present the results in discussion.

Jackson, T. L.↗

Engineering Microstructure in Dry-Processed Cathodes Via Calendering

Calendering serves as a multifunctional step in dry electrode processing that not only densifies the electrode but also induces polytetrafluoroethylene (PTFE) fibrillation and reorganizes the microstructure. These coupled effects are essential for achieving electrical connectivity and sufficient cohesion, yet they also introduce trade-offs, such as active material particle fracture, pore collapse, and excessive porosity loss, that can hinder ionic transport. This research systematically maps the calendering parameter space for LiNi0.6Mn0.2Co0.2O2 (NMC622) dry cathodes with a target thickness of ∼100 µm and porosity of ∼30% by varying roll gaps, roll temperature, roll speed, and the number of passes. A practical processing window for this formulation and electrode architecture is identified that achieves sufficient PTFE fibrillation and strong interfacial contact while minimizing particle fracture and preserving the porosity required for efficient ionic transport. In particular, gradual-gap calendering with moderate per-pass compression mitigates fracture and pore collapse while still reaching the target thickness with reasonable throughput, and slower roll speeds with modest roll temperatures further reduce mechanical damage. These results provide actionable guidance for scaling NMC622-based thick dry-processed cathodes.

Park, Hyunji↗

Experimental ball bearing dynamics study

A photographic method was employed to record the kinematic performance of rolling elements in turbo machinery ball bearings. The 110 mm split inner ring test bearings had nominal contact angles of 26 deg and 34 deg. High speed films were taken at inner ring speeds of 4,000, 8,000 and 12,000 rpm and at thrust loads of 4,448 N and 22,240 N (1,000 and 5,000 lbs). The films were measured and this data reduced to obtain separator speed, ball speed and ball spin axis orientation.

Signer, H. R.↗

Wear reduction in ceramic bearings by surface generated pyrolytic carbon continuously replenished by ethylene gas

Sliding tests with a pin-on-disc tribometer and both sliding and rolling tests with a modified four-ball tester at bulk temperatures of about 500 C and contact pressures of about 2.2 GPa have demonstrated up to 80% reductions of friction and wear with silicon nitride surfaces when a stream of ethylene is directed into the conjunction region. The effects are even more pronounced when the ethylene is prenucleated by a flow over a coil of nichrome wire electrically heated to about 800 C and located about 30 cm upstream of the exit nozzle. Steel and Ni-plated steel are lubricated by this method even more efficiently at lower temperatures.

Lauer, J. L.↗

NASA Tech Briefs, November 2007

Topics include: Wireless Measurement of Contact and Motion Between Contact Surfaces; Wireless Measurement of Rotation and Displacement Rate; Portable Microleak-Detection System; Free-to-Roll Testing of Airplane Models in Wind Tunnels; Cryogenic Shrouds for Testing Thermal-Insulation Panels; Optoelectronic System Measures Distances to Multiple Targets; Tachometers Derived From a Brushless DC Motor; Algorithm-Based Fault Tolerance for Numerical Subroutines; Computational Support for Technology- Investment Decisions; DSN Resource Scheduling; Distributed Operations Planning; Phase-Oriented Gear Systems; Freeze Tape Casting of Functionally Graded Porous Ceramics; Electrophoretic Deposition on Porous Non- Conductors; Two Devices for Removing Sludge From Bioreactor Wastewater; Portable Unit for Metabolic Analysis; Flash Diffusivity Technique Applied to Individual Fibers; System for Thermal Imaging of Hot Moving Objects; Large Solar-Rejection Filter; Improved Readout Scheme for SQUID-Based Thermometry; Error Rates and Channel Capacities in Multipulse PPM; Two Mathematical Models of Nonlinear Vibrations; Simpler Adaptive Selection of Golomb Power-of- Two Codes; VCO PLL Frequency Synthesizers for Spacecraft Transponders; Wide Tuning Capability for Spacecraft Transponders; Adaptive Deadband Synchronization for a Spacecraft Formation; Analysis of Performance of Stereoscopic-Vision Software; Estimating the Inertia Matrix of a Spacecraft; Spatial Coverage Planning for Exploration Robots; and Increasing the Life of a Xenon-Ion Spacecraft Thruster.

Source record↗

Rolling-element fatigue life of AISI M-50 and 18-4-1 balls

Rolling element fatigue studies were conducted with AISI M-50, EFR 18-4-1, and VAR 18-4-1. Groups of 12.7 mm (1/2-in) diameter balls of each material were tested in the five ball fatigue tester. Test conditions included a load of 1540 N (347 lbf) giving a maximum Hertz stress of 5520 MPa (800 000 psi), a shaft speed of 10,700 rpm, and a contact angle of 30 deg. Tests were run at a race temperature of 339 K (150 F) with a type 2 ester lubricant. The rolling element fatigue life of AISI M-50 was not significantly different from that of EFR 18-4-1 or VAR 18-4-1 based on a statistical comparison of the test results.

Parker, R. J.↗

Resilient and Corrosion-Proof Rolling Element Bearings Made from Superelastic Ni-Ti Alloys for Aerospace Mechanism Applications

Mechanical components (bearings, gears, mechanisms) typically utilize hard materials to minimize wear and attain long life. In such components, heavily loaded contact points (e.g., meshing gear teeth, bearing ball-raceway contacts) experience high contact stresses. The combination of high hardness, heavy loads and high elastic modulus often leads to damaging contact stress. In addition, mechanical component materials, such as tool steel or silicon nitride exhibit limited recoverable strain (typically less than 1 percent). These material attributes can lead to Brinell damage (e.g., denting) particularly during transient overload events such as shock impacts that occur during the launching of space vehicles or the landing of aircraft. In this paper, a superelastic alloy, 60NiTi, is considered for rolling element bearing applications. A series of Rockwell and Brinell hardness, compressive strength, fatigue and tribology tests are conducted and reported. The combination of high hardness, moderate elastic modulus, large recoverable strain, low density, and intrinsic corrosion immunity provide a path to bearings largely impervious to shock load damage. It is anticipated that bearings and components made from alloys with such attributes can alleviate many problems encountered in advanced aerospace applications.

DellaCorte, Christopher↗

Cross flow in a starved EHD contact

It is suggested that fluid film thickness in a starved EHD contact is determined by the rate at which lubricant is forced from the Hertz zone normal to the rolling direction. A simple model allows calculation of this flow rate, together with related quantities of interest to the designer.

Kingsbury, E.↗