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At least 469 records · Page 26

Experimental investigations of elastohydrodynamic lubrication

Various experimental studies of elastohydrodynamic lubrication have been reviewed. The various types of machines used in these investigations, such as the disc, two and four ball, crossed-cylinders, and crossed-axes rolling disc machine, are described. The measurement of the most important parameters, such as film shape, film thickness, pressure, temperature, and traction, is considered. Determination of the film thickness is generally the most important of these effects since it dictates the extent to which the asperities on opposing surfaces can come into contact and thus has a direct bearing on wear and fatigue failure of the contacting surfaces. Several different techniques for measuring film thickness have been described, including electrical resistance, capacitance, X-ray, optical interferometry, laser beam diffraction, strain gage, and spring dynamometer methods. An attempt has been made to describe the basic concepts and limitations of each of these techniques. These various methods have been used by individual researchers, but there is no universally acceptable technique for measuring elastohydrodynamic film thickness. Capacitance methods have provided most of the reliable data for nominal line or rectangular conjunctions, but optical interferometry has proved to be the most effective procedure for elliptical contacts. Optical interferometry has the great advantage that it reveals not only the film thickness, but also details of the film shape over the complete area of the conjunction.

Hamrock, B. J.↗

Incorporating general race and housing flexibility and deadband in rolling element bearing analysis

Methods for including the effects of general race and housing compliance and outer race-to-housing deadband (clearance) in rolling element bearing mechanics analysis is presented. It is shown that these effects can cause significant changes in bearing stiffness characteristics, which are of major importance in rotordynamic response of turbomachinery and other rotating systems. Preloading analysis is demonstrated with the finite element/contact mechanics hybrid method applied to a 45 mm angular contact ball bearing.

Davis, R. R.↗

Effect of Roller Geometry on Roller Bearing Load-Life Relation

Cylindrical roller bearings typically employ roller profile modification to equalize load distribution, minimize stress concentration at roller ends and allow for a small amount of misalignment. The 1947 Lundberg-Palmgren analysis reported an inverse fourth power relation between load and life for roller bearings with line contact. In 1952, Lundberg and Palmgren changed their load-life exponent to 10/3 for roller bearings, assuming mixed line and point contact. The effect of roller-crown profile was reanalyzed in this paper to determine the actual load-life relation for modified roller profiles. For uncrowned rollers (line contact), the load-life exponent is p = 4, in agreement with the 1947 Lundberg-Palmgren value but crowning reduces the value of the exponent, p. The lives of modern roller bearings made from vacuum-processed steels significantly exceed those predicted by the Lundberg-Palmgren theory. The Zaretsky rolling-element bearing life model of 1996 produces a load-life exponent of p = 5 for flat rollers, which is more consistent with test data. For the Zaretsky model with fully crowned rollers p = 4.3. For an aerospace profile and chamfered rollers, p = 4.6. Using the 1952 Lundberg-Palmgren value p = 10/3, the value incorporated in ANSI/ABMA and ISO bearing standards, can create significant life calculation errors for roller bearings.

Roller bearing↗

Corrosion prevention of cold rolled steel using water dispersible lignosulfonic acid doped polyaniline

The invention provides coatings useful for preventing corrosion of metals. The coatings comprise a film-forming resin and conductive polymers comprising linearly conjugated .pi.-systems and residues of sulfonated lignin or a sulfonated polyflavonoid or derivatives of solfonated lignin or a sulfonated polyflavonoid. The invention also provides a latex formulation of the coatings, and articles of manufacture comprising a metal substrate and a coating in contact with the metal substrate.

Viswanathan, Tito↗

Evaluation of slip-traction characteristics of polymeric transfer films

Experiments carried out on Batelle's rolling disk apparatus to determine the traction characteristics of polymeric transfer films developed under cryogenic conditions are described. The analyses reveal that the presence of a soft layer can significantly decrease the slope of the traction curves in a bearing. The measurement of low traction indicates the presence of soft layer in the contact zone; if this thin film can be maintained, the bearing stability may be maintained.

Barber, S. A.↗

Bearing elastohydrodynamic lubrication: A complex calculation made simple

The lubricant elastohydrodynamic (EHD) film thickness formula is reduced to a simplified form whereby only the rolling-element bearing inside and outside diameters and speed (in revolutions per minute) and the lubricant type and viscosity (in centipoise) at temperature are required for its use. Additionally, a graph is provided for the first time that is based upon experimental data giving an EHD film reduction factor as a function of contact lubricant flow number. This reduction factor accounts for lubricant starvation within the Hertzian contact. A graph relating the ratio of minimum film thickness to composite surface roughness and a lubrication-life correction factor is also provided. The life correction factor is used to determine resultant bearing life.

Zaretsky, Erwin V.↗

Defining an Abrasion Index for Lunar Surface Systems as a Function of Dust Interaction Modes and Variable Concentration Zones

Unexpected issues were encountered during the Apollo era of lunar exploration due to detrimental abrasion of materials upon exposure to the fine-grained, irregular shaped dust on the surface of the Moon. For critical design features involving contact with the lunar surface and for astronaut safety concerns, operational concepts and dust tolerance must be considered in the early phases of mission planning. To systematically define material selection criteria, dust interaction can be characterized by two-body or three-body abrasion testing, and subcategorically by physical interactions of compression, rolling, sliding and bending representing specific applications within the system. Two-body abrasion occurs when a single particle or asperity slides across a given surface removing or displacing material. Three-body abrasion occurs when multiple particles interact with a solid surface, or in between two surfaces, allowing the abrasives to freely rotate and interact with the material(s), leading to removal or displacement of mass. Different modes of interaction are described in this paper along with corresponding types of tests that can be utilized to evaluate each configuration. In addition to differential modes of abrasion, variable concentrations of dust in different zones can also be considered for a given system design and operational protocol. These zones include: (1) outside the habitat where extensive dust exposure occurs, (2) in a transitional zone such as an airlock or suitport, and (3) inside the habitat or spacesuit with a low particle count. These zones can be used to help define dust interaction frequencies, and corresponding risks to the systems and/or crew can be addressed by appropriate mitigation strategies. An abrasion index is introduced that includes the level of risk, R, the hardness of the mineralogy, H, the severity of the abrasion mode, S, and the frequency of particle interactions, F.

Kobrick, Ryan L.↗

CORROSION PREVENTION OF COLD ROLLED STEEL USING WATER DISPERSIBLE LIGNOSULFONIC ACID DOPED POLYANILINE

The invention provides coatings useful for preventing corrosion of metals. The coatings comprise a film-forming resin and conductive polymers comprising linearly conjugated pi-systems and residues of sulfonated lignin or a sulfonated polyflavonoid or derivatives of sulfonated lignin or a sulfonated polyflavonoid. The invention also provides a latex formulation of the coatings, and articles of manufacture comprising a metal substrate and a coating in contact with the metal substrate.

Viswanathan, Tito↗

Corrosion Prevention of Cold Rolled Steel Using Water Dispersible Lignosulfonic Acid Doped Polyaniline

The invention provides coatings useful for preventing corrosion of metals. The coatings comprise a film-forming resin and conductive polymers comprising linearly conjugated x-systems and residues of sulfonated lignin or a sulfonated polyflavonoid or derivatives of solfonated lignin or a sulfonated polyflavonoid. The invention also provides a latex formulation of the coatings, and articles of manufacture comprising a metal substrate and a coating in contact with the metal substrate.

Viswanathan, Tito↗

Bearing, gearing, and lubrication technology

Results of selected NASA research programs on rolling-element and fluid-film bearings, gears, and elastohydrodynamic lubrication are reported. Advances in rolling-element bearing material technology, which have resulted in a significant improvement in fatigue life, and which make possible new applications for rolling bearings, are discussed. Research on whirl-resistant, fluid-film bearings, suitable for very high-speed applications, is discussed. An improved method for predicting gear pitting life is reported. An improved formula for calculating the thickness of elastohydrodynamic films (the existence of which help to define the operating regime of concentrated contact mechanisms such as bearings, gears, and cams) is described.

Anderson, W. J.↗

Bearing, gearing, and lubrication technology

Results of selected NASA research programs on rolling-element and fluid-film bearings, gears, and elastohydrodynamic lubrication are reported. Advances in rolling-element bearing material technology, which have resulted in a significant improvement in fatigue life, and which make possible new applications for rolling bearings, are discussed. Research on whirl-resistant, fluid-film bearings, suitable for very high-speed applications, is discussed. An improved method for predicting gear pitting life is reported. An improved formula for calculating the thickness of elastohydrodynamic films (the existence of which help to define the operating regime of concentrated contact mechanisms such as bearings, gears, and cams) is described.

Anderson, W. J.↗

Critical Issues for Cu(InGa)Se2 Solar Cells on Flexible Polymer Web

Elemental in-line evaporation on glass substrates has been a viable process for the large-area manufacture of CuInSe2-based photovoltaics, with module efficiencies as high as 12.7% [1]. However, lightweight, flexible CuInSe2-based modules are attractive in a number of applications, such as space power sources. In addition, flexible substrates have an inherent advantage in manufacturability in that they can be deposited in a roll-to-roll configuration allowing continuous, high yield, and ultimately lower cost production. As a result, high-temperature polymers have been used as substrates in depositing CuInSe2 films [2]. Recently, efficiency of 14.1% has been reported for a Cu(InGa)Se2-based solar cell on a polyimide substrate [3]. Both metal foil and polymer webs have been used as substrates for Cu(InGa)Se2-based photovoltaics in a roll-to-roll configuration with reasonable success [4,5]. Both of these substrates do not allow, readily, the incorporation of Na into the Cu(InGa)Se2 film which is necessary for high efficiency devices [3]. In addition, polymer substrates, can not be used at temperatures that are optimum for Cu(InGa)Se2 deposition. However, unlike metal foils, they are electrically insulating, simplifying monolithically-integrated module fabrication and are not a source of impurities diffusing into the growing film. The Institute of Energy Conversion (IEC) has modified its in-line evaporation system [6] from deposition onto glass substrates to roll-to-roll deposition onto polyimide (PI) film in order to investigate key issues in the deposition of large-area Cu(InGa)Se2 films on flexible polymer substrates. This transition presented unexpected challenges that had to be resolved. In this paper, two major problems, spitting from the Cu source and the cracking of Mo back contact film, will be discussed and the solution to each will be presented.

Eser, Erten↗

Positioning X-Ray Film By Balloon

Film rolled around deflated balloon before being inserted in duct. Clamped at end of segmented flexible cable and fed with balloon into duct to predetermined point where inspection made, as indicated by length of cable paid out. Inflated balloon holds x-ray film against inside wall of duct for radiographic inspection. Ensures film positioned in contact with welded joint far along duct from opening through which inserted, so clear x-ray image of joint obtained.

Windbiel, Frederich↗

Measuring Liquid Drop Properties on Nanoscale 1D Patterned Photoresist Structures

This communication reports liquid wetting properties of DI-water on one-dimensional nano-patterned photoresist lines atop a silicon substrate as the pattern period is varied from 0.3- to 1.0-µm. Both constant photoresist height and constant width/height ratios are investigated. The line/period ratio was fixed at 0.3 (0.4) for different measurement sequences. The surface of the photoresist was treated with a short CHF 3 reactive ion etch to ensure consistent hydrophobic photoresist: water surface energies. Average parallel contact angle (θ || ), average perpendicular contact angle (θ ⊥ ), drop width (W), and drop length (L) at constant volume were measured on nano-patterned surfaces fabricated with interferometric lithography. Both θ || and θ ⊥ contact angles increase as the period (0.3- to 1-μm) increases; the θ || spreading rate is faster than θ ⊥ due to pinning on the grooves resulting in an elongated drop shape. The traditional Wenzel and Cassie-Baxter models of drop contact angles were developed for isotropic random 2D roughness and do not account for the anisotropy induced by the 1D line patterns. The observed angular variations with period are not consistent with either model. Understanding liquid wetting properties and hydrophobicity on 1D silicon surfaces has many applications in lab-on-a-chip, micro/nano-fluidic devices, roll-to-roll nano-imprint fabrication, self-cleaning surfaces, and micro-reactors.

42 ENGINEERING↗

Laser-based characterization of nuclear fuel plates

Ensuring the integrity of fuel-clad and clad-clad bonding in nuclear fuels is important for safe reactor operation and assessment of fuel performance, yet the measurement of bond strengths in actual fuels has proved challenging. The laser shockwave technique (LST) originally developed to characterize structural adhesion in composites is being employed to characterize interface strength in a new type of plate fuel being developed at Idaho National Laboratory (INL). LST is a non-contact method that uses lasers for the generation and detection of large-amplitude acoustic waves and is well suited for application to both fresh and irradiated nuclear-fuel plates. This paper will report on initial characterization results obtained from fresh fuel plates manufactured by different processes, including hot isostatic pressing, friction stir welding, and hot rolling.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Development of electrical-erosion instrument for direct write micro-patterning on large area conductive thin films

We have developed a complete instrument to perform direct, dry, and cost-effective lithography on conductive materials, based on localized electrical discharges, which avoids using masks or chemicals typical of conventional photolithography. The technique is considered fully compatible with substrate transport based systems, like roll-to-roll technology. The prototype is based on two piezo nano-steppers coupled to three linear micro-stages to cover a large scale operation from micrometers to centimeters. The operation mode consists of a spring probe biased at low DC voltage with respect to a grounded conductive layer. The tip slides on the target layer keeping contact with the material in room conditions, allowing continuous electric monitoring of the process, and also real-time tilt correction via software. The sliding tip leaves an insulating path (limited by the tip diameter) along the material, enabling to draw electrically insulated tracks and pads. The physical principle of operation is based in the natural self-limitation of the discharge due to material removal or insulation. The so produced electrical discharges are very fast, in the range of μs, so features may be performed at speeds of few cm/s, enabling scalability to large areas. The instrument has been tested on different conducting materials as gold, indium tin oxide, and aluminum, allowing the fabrication of alphanumeric displays based on passive matrix of organic light emitting diodes without the use of masks or photoresists. We have verified that the highest potential is achieved on graphene, where no waste material is detected, producing excellent well defined edges. This allows manufacturing graphene micro-ribbons with a high aspect ratio up to 1200:1.

36 MATERIALS SCIENCE↗

Laser-Based Characterization of Nuclear Fuel Plates

Ensuring the integrity of fuel-clad and clad-clad bonding in nuclear fuels is important for safe reactor operation and assessment of fuel performance, yet the measurement of bond strengths in actual fuels has proved challenging. The laser shockwave technique (LST) originally developed to characterize structural adhesion in composites is being employed to characterize interface strength in a new type of plate fuel being developed at Idaho National Laboratory (INL). LST is a non-contact method that uses lasers for the generation and detection of large-amplitude acoustic waves and is well suited for application to both fresh and irradiated nuclear-fuel plates. This paper will report on initial characterization results obtained from fresh fuel plates manufactured by different processes, including hot isostatic pressing, friction stir welding, and hot rolling.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Ultrafine gradient microstructure induced by severe plastic deformation under sliding contact conditions in copper

Highlights: • Sliding contact produces a gradient microstructure by severe plastic deformation. • Nanohardness is increased strongly by grain size and dislocation hardening. • The texture components in the deformed layer correspond to pure shear. • Grain size distribution, boundary misorientation and KAM were analysed. • Strain induced effects compete with crystallisation to determine the microstructure. - Abstract: Sliding contact induces severe plastic deformation (SPD) at the surface of ductile materials and induces a microstructural gradient associated to a significant increase of hardness toward the surface. This gradient allows observing all stages of grain refinement in SPD, as illustrated here by the analysis of polycrystalline electrolytic copper tested in a coaxial tribometer. Materials tested in the cold-rolled state and after annealing were characterised by high-resolution electron backscattering diffraction and nano-indentation. The incremental plastic strain produces an ultrafine microstructure in the top layers, which gradually changes to the original size in unaffected material. In cold-rolled material, an intermediate recrystallised layer is observed. The separation of the Misorientation Angle Distribution (MAD) in a low-angle portion and a high angle portion allows characterising the accumulation of strain induced misorientation, while the Kernel Average Misorientation (KAM) provides information on the evolution of substructure at the finest levels. The results point toward a process where strain-induced effects compete continuously with recrystallisation, except for the surface layer in the cold-rolled material, where dynamic recrystallisation is dominant. Combining the information from KAM and subgrain size distribution, the measured hardness can be explained as a combination of grain size and dislocation hardening.

36 MATERIALS SCIENCE↗