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NASA NTRS2004

Friction and Wear Characteristics of a Modified Composite Solid Lubricant Plasma Spray Coating

LCR304 is a solid lubricant coating composed of Ni-10Cr, Cr2O3, BaF2-CaF2 and Ag and developed for dimensional stability in high temperature air. This coating is a modification of PS304, which differs in that the Ni-Cr constituent contains 20wt% Cr. The tribological characteristics of LCR304 were evaluated by pin-on-disk and foil air bearing rig testing from 25 to 650 C and compared to previous test results with PS304. For both tests, the friction coefficient decreased as temperature increased from 25 to 650 C. Wear generally decreased with increasing temperature for all pin-on-disk tests. LCR304 coated components produced the least wear of Inconel X-750 counterface materials at 427 and 650 C. These results indicate that the LCR304 coating has potential as a replacement for PS304 in, for example, low cycle (minimum wear) applications where dimensional stability is imperative.

Stanford, M. K.↗

NASA NTRS1984

Report of the Panel on Aerodynamics

Progress in aerodynamics over the past 50 years has been evidenced by the development of increasingly sophisticated and efficient flight vehicles throughout the flight spectrum. Advances have generally arisen in an evolutionary manner from experience gained in wind tunnel testing, flight testing, and improvements in analytical and computational capabilities. As a result of this evolutionary development, both military and commercial vehicles operate at a relatively high efficiency level. This observation plus the fact that airplanes have not changed appreciably in outward appearance over recent years has led some skeptics to conclude incorrectly that aerodynamics is a mature technology, with little to be gained from further developments in the field. It is of interest to note that progress in aerodynamics has occurred without a thorough understanding of the fundamental physics of flow, turbulence, vortex dynamics, and separated flow, for example. The present understanding of transition, turbulence, and boundary layer separation is actually very limited. However, these fundamental flow phenomena provide the key to reducing the viscous drag of aircraft. Drag reduction provides the greatest potential for increased flight efficiency from the standpoint of both saving energy and maximizing performance. Recent advances have led to innovative concepts for reducing turbulent friction drag by modifying the turbulent structure within the boundary layer. Further advances in this basic area should lead to methods for reducing skin friction drag significantly. The current challenges for military aircraft open entirely new fields of investigation for the aerodynamicist. The ability through very high speed information processing technology to totally integrate the flight and propulsion controls can permit an aircraft to fly with "complete abandon," avoiding departure, buffet, and other undesirable characteristics. To utilize these new control concepts, complex aerodynamic phenomena will have to be understood, predicted, and controlled. Current requirements for military aircraft include configuration optimization through a widened envelope from subsonic to supersonic and from low to high angles of attack. This task is further complicated by requirements for control of observables. These challenging new designs do not have the luxury of a large experimental data base from which to optimize for various parameter combinations. Consequently, there exists a strong need for better techniques, both experimental and computational, to permit design optimization in a complete sense.

Bradley, Richard G.↗

NASA NTRS1986

Ground vibration test of an F-16 airplane with modified decoupler pylons

The decoupler pylon is a passive wing/store flutter suppression device. It was modified to reduce friction following initial flight tests. A ground vibration test was conducted on an F-16 aircraft loaded on each wing with a one-half-full (center bay empty) 370-gallon fuel tank mounted on a standard pylon, a GBU-8 store mounted on the decoupler pylon, and an AIM-9J missile mounted on a wingtip launcher. The test was conducted prior to flight tests with the modified pylon to determine modal frequencies, mode shapes, and structural damping coefficients. Data presented include frequency response plots, mode shape plots, and limited force-effect plots.

Cazier, F. W., Jr..↗

NASA NTRS2006

The Effects of Laser Peening and Shot Peening on Mechanical Properties in Friction Stir Welded 7075-T7351 Aluminum

Peening techniques like laser peening and shot peening were used to modify the surface of friction stir welded 7075-T7351 Aluminum Alloy specimens. The tensile coupons were machined such as the loading was applied in a direction perpendicular to the weld direction. The peening effects on the global and local mechanical properties through the different regions of the weld were characterized and assessed. The surface hardness levels resulting from various peening techniques were also investigated for both sides of the welds. Shot peening resulted in an increase to surface hardness levels, but no improvement was noticed on the mechanical properties. In contrast, mechanical properties were improved by laser peening when compared to the unpeened material.

Hatamleh, Omar↗

DOE OSTI2022

BDEM (Discrete-element-simulator for high-solids granular flows) [SWR-22-72]

BDEM is a discrete element method based simulation tool developed specifically for modeling high-solids granular flows that include polydispersity, heat-transfer, moving boundaries and chemistry. Our solver provides facilities for simulating spherical/non-spherical particles with modified contact and friction models in complex dynamic geometries defined using level-sets or triangulated files. The solver is developed on top of NREL's open-source performance portable library, AMReX, providing parallel execution capabilities on current and upcoming high-performance-computing (HPC) architectures. Simulations at the scale of several millions to billion particles have been performed using this software on large scale computing resources. This software can be applied to non-reacting solids dominant flows in silos, hoppers and screw conveyors as well as in high temperature reacting systems such as screw kilns and auger reactors.

Sitaraman, Hariswaran↗

NASA NTRS2000

Thermal-Flow Code for Modeling Gas Dynamics and Heat Transfer in Space Shuttle Solid Rocket Motor Joints

A new, thermal-flow simulation code, called SFLOW. has been developed to model the gas dynamics, heat transfer, as well as O-ring and flow path erosion inside the space shuttle solid rocket motor joints by combining SINDA/Glo, a commercial thermal analyzer. and SHARPO, a general-purpose CFD code developed at Thiokol Propulsion. SHARP was modified so that friction, heat transfer, mass addition, as well as minor losses in one-dimensional flow can be taken into account. The pressure, temperature and velocity of the combustion gas in the leak paths are calculated in SHARP by solving the time-dependent Navier-Stokes equations while the heat conduction in the solid is modeled by SINDA/G. The two codes are coupled by the heat flux at the solid-gas interface. A few test cases are presented and the results from SFLOW agree very well with the exact solutions or experimental data. These cases include Fanno flow where friction is important, Rayleigh flow where heat transfer between gas and solid is important, flow with mass addition due to the erosion of the solid wall, a transient volume venting process, as well as some transient one-dimensional flows with analytical solutions. In addition, SFLOW is applied to model the RSRM nozzle joint 4 subscale hot-flow tests and the predicted pressures, temperatures (both gas and solid), and O-ring erosions agree well with the experimental data. It was also found that the heat transfer between gas and solid has a major effect on the pressures and temperatures of the fill bottles in the RSRM nozzle joint 4 configuration No. 8 test.

Wang, Qunzhen↗

NASA NTRS1982

Modified gauge for time-resolved skin-friction measurements

A new gauge for skin-friction measurements in turbulent flows involving a wire close to the surface and a second, flush-mounted film which serves as a constant temperature guard heater is described and evaluated. It is shown that a laminar calibration of the gauge applies to measurements in turbulent flow and that the frequency response of the gauge is appropriate for time-resolved data in such a flow. Initial results from a turbulent channel flow are presented.

Ajagu, C. O.↗

NASA NTRS2017

Development and Testing of a Friction-Based Post-Installable Fiber-Optic Monitoring System for Subsea Applications

This paper presents the design and development of a friction-based coupling device for a fiber-optic monitoring system capable of measuring pressure, strain, and temperature that can be deployed on existing subsea structures. A summary is provided of the design concept, prototype development, prototype performance testing, and subsequent design refinements of the device. The results of laboratory testing of the first prototype performed at the National Aeronautics and Space Administration (NASA) Johnson Space Center (JSC) are also included. Limitations of the initial concept were identified during testing and future design improvements were proposed and later implemented. These new features enhance the coupling of the sensor device and improve the monitoring system measurement capabilities. A major challenge of a post-installed instrumentation monitoring system is to ensure adequate coupling between the instruments and the structure of interest for reliable measurements. Friction-based devices have the potential to overcome coupling limitations caused by marine growth and soil contamination on flowlines, risers, and other subsea structures. The work described in this paper investigates the design and test of a friction-based coupling device (herein referred to as a friction clamp) which is suitable for pipelines and structures that are suspended in the water column as well as for those that are resting on the seabed. The monitoring elements consist of fiberoptic sensors that are bonded to a stainless steel clamshell assembly with a high-friction surface coating. The friction clamp incorporates a single hinge design to facilitate installation of the clamp and dual rows of opposing fasteners to distribute the clamping force along the structure. The friction clamp can be modified to be installed by commercial divers in shallow depths or by remotely operated vehicles in deep-water applications. NASA-JSC was involved in the selection and testing of the friction coating, and in the design and testing of the prototype clamp device. Four-inch diameter and eight-inch diameter sub-scale friction clamp prototypes were built and tested to evaluate the strain measuring capabilities of the design under different loading scenarios. The testing revealed some limitations of the initial design concept, and subsequent refinements were explored to improve the measurement performance of the system. This study was part of a collaboration between NASA-JSC and Astro Technology Inc. within a study called Clear Gulf. The primary objective of the Clear Gulf study is to develop advanced instrumentation technologies that will improve operational safety and reduce the risk of hydrocarbon spillage. NASA provided unique insights, expansive test facilities, and technical expertise to advance technologies that will benefit the environment, the public, and commercial industries.

Bentley, Nicole L.↗

NASA NTRS1994

Drag reduction strategies

previously a description was given of an active control scheme using wall transpiration that leads to a 15% reduction in surface skin friction beneath a turbulent boundary layer, according to direct numerical simulation. In this research brief further details of that scheme and its variants are given together with some suggestions as to how sensor/actuator arrays could be configured to reduce surface drag. The research which is summarized here was performed during the first half of 1994. This research is motivated by the need to understand better how the dynamics of near-wall turbulent flow can be modified so that skin friction is reduced. The reduction of turbulent skin friction is highly desirable in many engineering applications. Experiments and direct numerical simulations have led to an increased understanding of the cycle of turbulence production and transport in the boundary layer and raised awareness of the possibility of disrupting the process with a subsequent reduction in turbulent skin friction. The implementation of active feedback control in a computational setting is a viable approach for the investigation of the modifications to the flow physics that can be achieved. Bewley et al. and Hill describe how ideas from optimal control theory are employed to give 'sub-optimal' drag reduction schemes. The objectives of the work reported here is to investigate in greater detail the assumptions implicit within such schemes and their limitations. It is also our objective to describe how an array of sensors and actuators could be arranged and interconnected to form a 'smart' surface which has low skin friction.

Hill, D. Christopher↗

NASA NTRS1956

Charts Adapted from Van Driest's Turbulent Flat-plate Theory for Determining Values of Turbulent Aerodynamic Friction and Heat-transfer Coefficients

A modified method of Van Driest's flat-plate theory for turbulent boundary layer has been found to simplify the calculation of local skin-friction coefficients which, in turn, have made it possible to obtain through Reynolds analogy theoretical turbulent heat-transfer coefficients in the form of Stanton number. A general formula is given and charts are presented from which the modified method can be solved for Mach numbers 1.0 to 12.0, temperature ratios 0.2 to 6.0, and Reynolds numbers 0.2 times 10 to the 6th power to 200 times 10 to the 6th power.

HEAT TRANSFER, AERODYNAMIC↗

DOE OSTI2023

Enhanced internal condensation of R1233zd(E) on micro- and nanostructured copper and aluminum surfaces

In-tube condensation of refrigerants is an important process which affects thermal efficiency in many applications, ranging from refrigeration and air conditioning to electronics thermal management. In-tube heat transfer and pressure drop are important to heat exchanger sizing and design. Here, in this work, micro- and nanostructured surfaces are applied to the internal wetted areas of copper and aluminum mini-channels to enhance the condensation heat transfer coefficient of hydrofluorocarbon R1233zd(E) refrigerant. To achieve scalable nanomanufacturing, surfaces were uniformly structured by relying on hydrochloric acid etching of aluminum and chemical oxidation of copper. The etched aluminum surfaces exhibited a 150% increase in heat transfer coefficient compared to smooth aluminum channels at specific qualities, with a 66% heat transfer coefficient improvement for complete phase change from saturated vapor to saturated liquid. Copper oxide structures showed no discernable difference in thermal-hydraulic performance when compared to smooth copper channels. Critical dimensionless parameters governing the heat transfer enhancement were identified by varying the tube internal diameter (2.3 mm to 4.7 mm), refrigerant mass flux (50 to 300 kg/(m 2 ·s)), and refrigerant quality (0 to 1). The dimensionless parameters include the Bond number normalized to the condensate film thickness, and the Weber number modified by the vapor friction factor. The relatively small increase in pressure drop (< 10%) associated with these surface enhancements further supports the promise of this method. The scalable and cost-effective techniques used to create these aluminum microstructures may reduce manufacturing cost when compared with current enhancement approaches such as extrusion, drawing, and welding.

42 ENGINEERING↗

NASA NTRS1996

The Effect of Compositional Tailoring on the Thermal Expansion and Tribological Properties of PS300: A Solid Lubricant Composite Coating

This paper describes a research program in which the goal is to alter the thermal expansion coefficient of a composite solid lubricant coating, PS300, by compositional tailoring. PS300 is a plasma sprayed coating consisting of chrome oxide, silver and barium fluoride/calcium fluoride eutectic in NiCr binder. By adjusting the composition, the thermal expansion coefficient can be altered, and hence chosen, to more closely match a selected substrate preventing coating spallation at extreme temperatures. Thermal expansion coefficients (CTE) for a variety of compositions were measured from 25 to 800 C using a commercial dilatometer. The CTE's ranged from 7.0 to 13 x lO(exp -6)/deg C depending on the binder content. Subsequent tribological testing of a modified composition indicated that friction and wear properties were relatively insensitive to compositional tailoring.

DellaCorte, C.↗

NASA NTRS1978

In-flight Compressible Turbulent Boundary Layer Measurements on a Hollow Cylinder at a Mach Number of 3.0

Skin temperatures, shearing forces, surface static pressures, and boundary layer pitot pressures and total temperatures were measured on a hollow cylinder 3.04 meters long and 0.437 meter in diameter mounted beneath the fuselage of the YF-12A airplane. The data were obtained at a nominal free stream Mach number of 3.0 and at wall-to-recovery temperature ratios of 0.66 to 0.91. The free stream Reynolds number had a minimal value of 4.2 million per meter. Heat transfer coefficients and skin friction coefficients were derived from skin temperature time histories and shear force measurements, respectively. Boundary layer velocity profiles were derived from pitot pressure measurements, and a Reynolds analogy factor of 1.11 was obtained from the measured heat transfer and skin friction data. The skin friction coefficients predicted by the theory of van Driest were in excellent agreement with the measurements. Theoretical heat transfer coefficients, in the form of Stanton numbers calculated by using a modified Reynolds analogy between skin friction and heat transfer, were compared with measured values. The measured velocity profiles were compared to Coles' incompressible law-of-the-wall profile.

Quinn, R. D.↗

NASA NTRS1998

The Evaluation of a Modified Chrome Oxide Based High Temperature Solid Lubricant Coating for Foil Gas Bearings

This paper describes the friction and wear performance of PS304, a modified chrome oxide based coating, for foil gas bearings. PS304 contains 60 wt% NiCr binder, 20 wt% Cr2O3 hardener, and 10 wt% each Ag, and BaF2/CaF2 lubricants. For evaluation, the coating is plasma spray deposited onto test journals which are slid against a superalloy partial arc foil bearing. The test load was 10 KPa (1.5 psi) and the bearings were run under start/stop cyclic conditions. The data show good wear performance of the bearing, especially at temperatures above 25 deg. C. Bearing friction was moderate (micron approx. or equal to 0.4) over the entire temperature range. Based upon the results obtained, the PS304 coating has promise for high temperature, oil-free turbomachinery applications.

DellaCorte, Chris↗

DOE OSTI2024

Velocity Dependence of Rate‐And‐State Friction in Granular Fault Gouge and Implications for Slow‐Slip Events

Abstract The standard rate‐and‐state friction (RSF) has extensively captured frictional behaviors, but it fails to explain the velocity dependence of frictional stability transition and widespread slow‐slip events (SSEs) in experiments and nature adequately. An alternative microphysical Chen‐Niemeijer‐Spiers (CNS) model can well describe the velocity dependence of frictional behaviors of granular gouges. Using the original CNS model, standard RSF parameters can be quantified microphysically. However, some micro‐parameters are not easy to estimate quantitatively, making it difficult to extrapolate to natural and experimental conditions. Here, we simplify the microphysically‐derived RSF parameters including direct effect a , evolution effect b , and critical slip distance D c , as well as equivalent values ( a eq , b eq , and D eq ). The simplified friction parameters directly illustrate their velocity dependence, namely the essentially constant a , a eq , and D c , negatively velocity‐dependent b and b eq , as well as varying D eq for different laws. They are roughly consistent with experimental results in various fault gouges. A modified CNS model is further derived from the original CNS model, establishing a direct link between the standard RSF and CNS models. The modified CNS model exhibits virtually identical frictional behaviors to the original CNS, but differs from the standard RSF at large velocity perturbations. Moreover, the linearized stability analysis indicates that the critical stiffness for the modified CNS model is velocity‐dependent. Compared with the standard RSF, the modified CNS model not only explains the velocity dependence of frictional stability transition, but also exhibits a more gradual transition for SSEs with a broader range of stiffness ratios.

Geochemistry & Geophysics↗

NASA NTRS1992

Effect of fiber orientation on the fracture toughness of brittle matrix composites

The effective fracture toughness of brittle matrix materials can be increased through the addition of short, poorly bonded fibers which bridge the growing crack. The orientation distribution of the fibers is likely to be biased, and not in an ideal random or aligned state. A micromechanical model is formulated for the postcracking behavior using the force-displacement relation for an arbitrary fiber bridging a crack, the fiber orientation density function, and the fiber location density function. This model is then used to determine an effective traction law for the bridging fibers, as well as the steady state bridging toughness increment. In most cases, the results may be placed in the form of a product of the aligned fiber results times a modifying integrated orientation factor. The frictional shear stress on fiber pull-out is allowed to vary during pull-out, modeling the effects of matrix breakdown, fiber surface smoothing or wear debris accumulation. Results are presented for a variety of representative planar and three-dimensional fiber orientation states.

Jain, L. K.↗

NASA NTRS1959

A Method for Computing Turbulent Heat Transfer in the Presence of a Streamwise Pressure Gradient for Bodies in High-Speed Flow

A modified Reynolds analogy between skin friction and heat transfer which depends upon local pressure gradient is derived. Exact and approximate solutions are derived from the differential equations; the exact solution is applicable for arbitrary initial (transition) conditions and the approximate solution requires fully developed turbulent flow from stagnation point or leading edge. The exact solution (restricted to stagnation initial conditions) and the approximate solutions are shown to agree with one another within 5 percent when applied to several blunt shapes. The present solutions generally predict the measured heating rates on these bodies within the accuracy of the measurements provided transition began upstream of the peak heating region. The present solutions appear to be sufficiently accurate for design purposes.

Cohen, Nathaniel B.↗

NASA NTRS1999

Optical model methods of predicting nuclide production cross sections from heavy ion fragmentation

Quantum mechanical optical potential methods for calculating inclusive isotope and element production cross sections from the fragmenting of heavy nuclei by intermediate- and high-energy protons and heavy ions are presented based upon a modified abrasion-ablation-FSI (frictional spectator interaction) collision model. The abrasion stage is treated as a quantum mechanical knockout process that leaves the residual prefragment in an excited state. Prefragment excitation energies are estimated using a combined liquid drop and FSI method. In ablation the prefragment deexcites by particle and photon emission to produce the final fragment. Contributions from electromagnetic dissociation to single nucleon removal cross sections are incorporated using a Weiszacker-Williams theory that includes electric dipole and electric quadrupole interactions. Estimates of elemental and isotopic production cross sections are in good agreement with published cross section measurements for a variety of projectile-target-beam energy combinations.

NASA Discipline Radiation Health↗