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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 487 records · Page 27
All sourcesNASA NTRSDOE OSTI
NASA NTRS2001

Mechanical Components Branch Overview

Mr. James Zakrajsek, chief of the Mechanical Components Branch, presented an overview of research conducted by the branch. Branch members perform basic research on mechanical components and systems, including gears and bearings, turbine seals, structural and thermal barrier seals, and space mechanisms. The research is focused on propulsion systems for present and advanced aerospace vehicles. For rotorcraft and conventional aircraft, we conduct research to develop technology needed to enable the design of low noise, ultra safe geared drive systems. We develop and validate analytical models for gear crack propagation, gear dynamics and noise, gear diagnostics, bearing dynamics, and thermal analyses of gear systems using experimental data from various component test rigs. In seal research we develop and test advanced turbine seal concepts to increase efficiency and durability of turbine engines. We perform experimental and analytical research to develop advanced thermal barrier seals and structural seals for current and next generation space vehicles. In space mechanisms, we conduct fundamental research on lubricants, materials, components and mechanisms subjected to deep space and planetary environments.

Source record↗
NASA NTRS2002

Overview of Glenn Mechanical Components Branch Research

Mr. James Zakrajsek, chief of the Mechanical Components Branch, gave an overview of research conducted by the branch. Branch members perform basic research on mechanical components and systems, including gears and bearings, turbine seals, structural and thermal barrier seals, and space mechanisms. The research is focused on propulsion systems for present and advanced aerospace vehicles. For rotorcraft and conventional aircraft, we conduct research to develop technology needed to enable the design of low noise, ultra safe geared drive systems. We develop and validate analytical models for gear crack propagation, gear dynamics and noise, gear diagnostics, bearing dynamics, and thermal analyses of gear systems using experimental data from various component test rigs. In seal research we develop and test advanced turbine seal concepts to increase efficiency and durability of turbine engines. We perform experimental and analytical research to develop advanced thermal barrier seals and structural seals for current and next generation space vehicles. Our space mechanisms research involves fundamental investigation of lubricants, materials, components and mechanisms for deep space and planetary environments.

Zakrajsek, James↗
NASA NTRS2016

The International Space Station (ISS) Solar Alpha Rotary Joint (SARJ): Materials & Processes (M&P) Lessons Learned for a Large, Spacecraft Rotating Mechanism

The ISS utilizes two large rotating mechanisms, the SARJ, as part of the solar arrays alignment system for more efficient power generation. The SARJ is a 10.3m circumference, nitrided 15-5PH steel race ring of triangular cross-section, with 12 sets of trundle bearing assemblies transferring load across the rolling joint. The SARJ mechanism rotates continuously and slowly - once every orbit, or every 90 minutes. In 2008, the starboard SARJ suffered a lubrication failure, resulting in severe damage (spalling) of one of the race ring surfaces. Extensive effort was conducted to prevent the port SARJ from suffering the same failure, and fortunately was ultimately successful in recovering the functionality of the starboard SARJ. The M&P function was key in determining the cause of failure and the means for mechanism recovery. From a M&P lessons-learned perspective, observations are made concerning the original SARJ design parameters (boundary conditions), the perceived need for nitriding the race ring, the test conditions employed during qualification, the environmental controls used for the hardware preflight, and the lubrication robustness necessary for complex kinematic mechanisms expecting high-reliability and long-life.

Golden, Johnny L.↗
NASA NTRS2016

The International Space Station (ISS) Solar Alpha Rotary Joint (SARJ): Materials & Processes (M&P) Lessons Learned for a Large, Rotating Spacecraft Mechanism

The International Space Station (ISS) utilizes two large rotating mechanisms, the solar alpha rotary joints (SARJs), as part of the solar arrays' alignment system for more efficient power generation. Each SARJ is a 10.3m circumference, nitrided 15-5PH steel race ring of triangular cross-section, with 12 sets of trundle bearing assemblies transferring load across the rolling joint. The SARJ mechanism rotates continuously and slowly - once every orbit, or every 90 minutes. In 2007, the starboard SARJ suffered a lubrication failure, resulting in severe damage (spalling) to one of the race ring surfaces. Extensive effort was conducted to prevent the port SARJ from suffering the same failure, and fortunately that effort was ultimately successful in also recovering the functionality of the starboard SARJ. The M&P engineering function was key in determining the cause of failure and the means for mechanism recovery. From a M&P lessons-learned perspective, observations are made concerning the original SARJ design parameters (boundary conditions), the perceived need for nitriding the race ring, the test conditions employed during qualification, the environmental controls used for the hardware preflight, and the lubrication robustness necessary for complex kinematic mechanisms expecting high-reliability and long-life.

Golden, Johnny L.↗
NASA NTRS2017

Lessons Learned: Mechanical Component and Tribology Activities in Support of Return to Flight

The February 2003 loss of the Space Shuttle Columbia resulted in NASA Management revisiting every critical system onboard this very complex, reusable space vehicle in a an effort to Return to Flight. Many months after the disaster, contact between NASA Johnson Space Center and NASA Glenn Research Center evolved into an in-depth assessment of the actuator drive systems for the Rudder Speed Brake and Body Flap Systems. The actuators are CRIT 1-1 systems that classifies them as failure of any of the actuators could result in loss of crew and vehicle. Upon further evaluation of these actuator systems and the resulting issues uncovered, several research activities were initiated, conducted, and reported to the NASA Space Shuttle Program Management. The papers contained in this document are the contributions of many researchers from NASA Glenn Research Center and Marshall Space Flight Center as part of a Lessons Learned on mechanical actuation systems as used in space applications. Many of the findings contained in this document were used as a basis to safely Return to Flight for the remaining Space Shuttle Fleet until their retirement.

Tribology↗
NASA NTRS1975

Elastohydrodynamic lubrication in an instrument ball-bearing

The paper deals with experimental measurement of bearing torque and 'percentage of lubrication' in instrument size (R6) bearings. The primary parameter found to affect bearing performance for several lubricant investigations is base viscosity. Inference of EHD film thickness is made from the percentage of film measurements which are compared with X-ray data. A reasonable correlation between the two types of data is presented, thereby, paving the way toward the use of the more universally applicable percentage of film measurements for the determination of EHD conditions in real bearing systems.

Kannel, J. W.↗
NASA NTRS1987

Materials research and applications at NASA Lewis Research Center

The facilities and instruments of the Lewis Research Center specialized for materials research are discussed. The main objectives of the Center are to provide R & D relevant to main propulsion plants and auxiliary power systems for aeronautics, space, and energy conversion applications. The Center is concerned with microstructure-property relations and their effect on processing; intermetallic compounds and high temperature metal matrix composites; ceramics with improved reliability for use in heat engines; polymer matrix composites for aerospace applcations; understanding the high temperature corrosive attack in the hostile environments of aircraft, rockets, and other heat engines; high temperature lubrication and wear; and microgravity materials research. The various types of schemes and techniques, provided by the Center, for analyzing data are described.

Probst, H. B.↗
NASA NTRS1960

A Solid Film Lubricant Composition for Use at High Sliding Velocities in Liquid Nitrogen

Solid-lubricant-containing compositions can be of value as films and solid bodies for bearing and seal surfaces in low-temperature liquefied gases. An experimental composition including polytetrafluoroethylene (PTFE), an epoxy resin, and lithium-alumina-silicate was studied in friction, wear, and endurance experiments in liquid nitrogen (−320 F). This composition was formulated to approximate the thermal expansion of metals used in cryogenic systems. Hemisphere (3/6-in. radius) rider specimens were used and in most experiments the load was 1000 g. Films (0.005-in. thick) on disk specimens gave good endurance life, low rider wear, and desirable friction (f = 0.02 to 0.07). They functioned at a higher sliding velocity (no failure at 16, 000 ft/min) with copper rider specimens than with stainless steel riders (failure at 9000 ft/min). Solid rider material of the experimental composition had good friction and wear properties at sliding velocities above 4000 ft/min. It is important to use the experimental composition with mating materials having good thermal conductivity.

Wisander, D. W.↗
NASA NTRS1984

The ball bearing as a rheological test device

An angular-contact ball bearing provides an easily obtainable, precise mechanical system for rheological tests on thin films under high pressure. The test conditions are by definition similar to those found in practice. Accessible independent variables include size, pressure, bulk temperature, roughness, adsorbed surfactant, fluid type, fluid quantity, fluid supply rate, film thickness, entrainment velocity, transit time, and combined strain. Easily measured or inferred variables include slip, changes in film thickness with time (transients), strain rate, lubricant elastic modulus (thin film, high pressure), tractive force, lubricant chemical degradation rate, and lubricant degradation product. Methods for setting and obtaining these quantities in a bearing are discussed, together with experimental limitations on them.

Kingsbury, E.↗
NASA NTRS1988

The 25 kWe solar thermal Stirling hydraulic engine system: Conceptual design

The conceptual design and analysis of a solar thermal free-piston Stirling hydraulic engine system designed to deliver 25 kWe when coupled to a 11 meter test bed concentrator is documented. A manufacturing cost assessment for 10,000 units per year was made. The design meets all program objectives including a 60,000 hr design life, dynamic balancing, fully automated control, more than 33.3 percent overall system efficiency, properly conditioned power, maximum utilization of annualized insolation, and projected production costs. The system incorporates a simple, rugged, reliable pool boiler reflux heat pipe to transfer heat from the solar receiver to the Stirling engine. The free-piston engine produces high pressure hydraulic flow which powers a commercial hydraulic motor that, in turn, drives a commercial rotary induction generator. The Stirling hydraulic engine uses hermetic bellows seals to separate helium working gas from hydraulic fluid which provides hydrodynamic lubrication to all moving parts. Maximum utilization of highly refined, field proven commercial components for electric power generation minimizes development cost and risk.

White, Maurice↗
NASA NTRS1990

The effect of coatings and liners on heat transfer in a dry shaft-bush tribosystem

The temperatures due to frictional heating within a solid lubricated or coated journal bearing were analyzed by using a finite element method. A solid model of the shaft-bush tribocontact was generated with an eight-node, three-dimensional, first-order isoparametric heat-transfer element and the Patran solid modeler software. The Patmar (Patran-Marc) translator was used to help develop the Marc-based finite element program for the system; this software was used on the Cray X-MP supercomputer to perform a finite element analysis of the contact. The analysis was performed for various liner materials, for thin, hard, wear-resistant coated bearings, and for different geometries and thermal cooling boundary conditions. The analyses indicated that thermal conductivity of the liner or coating material is the most vital thermal parameter that controls the interface temperature. In addition to design variations, the proximity of the cooling source to the heat-flux-generating interface is critically important to the temperature control in the system.

Ghosh, Mihir K.↗
NASA NTRS2002

Mystery of Foil Air Bearings for Oil-free Turbomachinery Unlocked: Load Capacity Rule-of-thumb Allows Simple Estimation of Performance

The Oil-Free Turbomachinery team at the NASA Glenn Research Center has unlocked one of the mysteries surrounding foil air bearing performance. Foil air bearings are self-acting hydrodynamic bearings that use ambient air, or any fluid, as their lubricant. In operation, the motion of the shaft's surface drags fluid into the bearing by viscous action, creating a pressurized lubricant film. This lubricating film separates the stationary foil bearing surface from the moving shaft and supports load. Foil bearings have been around for decades and are widely employed in the air cycle machines used for cabin pressurization and cooling aboard commercial jetliners. The Oil-Free Turbomachinery team is fostering the maturation of this technology for integration into advanced Oil-Free aircraft engines. Elimination of the engine oil system can significantly reduce weight and cost and could enable revolutionary new engine designs. Foil bearings, however, have complex elastic support structures (spring packs) that make the prediction of bearing performance, such as load capacity, difficult if not impossible. Researchers at Glenn recently found a link between foil bearing design and load capacity performance. The results have led to a simple rule-of-thumb that relates a bearing's size, speed, and design to its load capacity. Early simple designs (Generation I) had simple elastic (spring) support elements, and performance was limited. More advanced bearings (Generation III) with elastic supports, in which the stiffness is varied locally to optimize gas film pressures, exhibit load capacities that are more than double those of the best previous designs. This is shown graphically in the figure. These more advanced bearings have enabled industry to introduce commercial Oil-Free gas-turbine-based electrical generators and are allowing the aeropropulsion industry to incorporate the technology into aircraft engines. The rule-of-thumb enables engine and bearing designers to easily size and select bearing technology for a new application and determine the level of complexity required in the bearings. This new understanding enables industry to assess the feasibility of new engine designs and provides critical guidance toward the future development of Oil-Free turbomachinery propulsion systems.

DellaCorte, Christopher↗
NASA NTRS2018

Lessons Learned in the Flight Qualification of the S-NPP and NOAA-20 Solar Array Mechanisms

Deployable solar arrays are the energy source used on almost all Earth orbiting spacecraft and their release and deployment are mission-critical; fully testing them on the ground is a challenging endeavor. The 8 meter long deployable arrays flown on two sequential NASA weather satellites were each comprised of three rigid panels almost 2 meters wide. These large panels were deployed by hinges comprised of stacked constant force springs, eddy current dampers, and were restrained through launch by a set of four releasable hold-downs using shape memory alloy release devices. The ground qualification testing of such unwieldy deployable solar arrays, whose design was optimized for orbital operations, proved to be quite challenging and provides numerous lessons learned. A paperwork review and follow-up inspection after hardware storage determined that there were negative torque margins and missing lubricant, this paper will explain how these unexpected issues were overcome. The paper will also provide details on how the hinge subassemblies, the fully-assembled array, and mechanical ground support equipment were subsequently improved and qualified for a follow-on flight with considerably less difficulty. The solar arrays built by Ball Aerospace Corp. for the Suomi National Polar Partnership (SNPP) satellite and the Joint Polar Satellite System (JPSS-1) satellite (now NOAA-20) were both successfully deployed on-obit and are performing well.

Sexton, Adam↗
NASA NTRS1984

Temperature Effects in Elastohydrodynamically Lubricated Contacts

This paper gives an overview of our current understanding of thermal phenomena in elastohydrodynamic contacts and suggests some avenues for fruitful research in the next decade. Typical measured temperatures are presented for representative conditions and ranges of operating parameters. Temperatures can range from bulk ambient temperature to several hundred degrees centigrade in fully separated elastohydrodynamic films. Although attention in the past decade has been on the full film for the purposes of understanding film thickness and traction phenomena, the more interesting conditions are in the mixed elastohydrodynamic films. These mixed conditions are both common in tribological systems and they are the conditions that border on unsuccessful run-in and failure of the elastohydrodynamic contact. In mixed film conditions local hotspots can have temperatures of the order of 1888 C which cause increased reactivity of the surfaces with surrounding materials as well as changes of the surface physical properties so important to the operation of concentrated contacts. An additional area discussed is that of the bulk system thermal transients which occur in tribological systems. These transients are frequently long in duration and have a direct bearing on the elastohydrodynamic film thickness and traction.

Ward O Winer↗
NASA NTRS1976

Gas-path seal technology

Improved gas-path seals are needed for better fuel economy, longer performance retention, and lower maintenance, particularly in advanced, high-performance gas turbine engines. Problems encountered in gas-path sealing are described, as well as new blade-tip sealing approaches for high-pressure compressors and turbines. These include a lubricant coating for conventional, porous-metal, rub-strip materials used in compressors. An improved hot-press metal alloy shows promise to increase the operating surface temperatures of high-pressure-turbine, blade-tip seals to 1450 K (2150 F). Three ceramic seal materials are also described that have the potential to allow much higher gas-path surface operating temperatures than are possible with metal systems.

Zuk, J.↗
NASA NTRS1993

Mechanical energy absorber

An energy absorbing system for controlling the force where a moving object engages a stationary stop and where the system utilized telescopic tubular members, energy absorbing diaphragm elements, force regulating disc springs, and a return spring to return the telescoping member to its start position after stroking is presented. The energy absorbing system has frusto-conical diaphragm elements frictionally engaging the shaft and are opposed by a force regulating set of disc springs. In principle, this force feedback mechanism serves to keep the stroking load at a reasonable level even if the friction coefficient increases greatly. This force feedback device also serves to desensitize the singular and combined effects of manufacturing tolerances, sliding surface wear, temperature changes, dynamic effects, and lubricity.

Wesselski, Clarence J.↗
NASA NTRS1980

Dynamic characteristics of a high-speed rotor with radial and axial foil-bearing supports

An asymmetric rotor (19N; 4.3 lb), supported radially and axially by compliant bearings is subjected to severe excitation by rotating unbalance in the 'pitching' mode at speeds to 50,000 rpm. The resilient, air-lubricated bearings provide very effective damping, so that regions of resonance and instability can be traversed with amplitudes and limit-trajectories within acceptable bounds. A novel journal bearing is introduced, in which a resilient support is furnished by the outer turn of the coiled foil-element bent to form an open polygon. The experimental apparatus and procedure are described, and the response of the rotor and flexible support system are documented by oscilloscope records of motion.

Licht, L.↗
NASA NTRS2018

Lessons Learned in the Flight Qualification of the S-NPP and NOAA-20 Solar Array Mechanisms

Deployable solar arrays are the energy source used on almost all Earth orbiting spacecraft and their release and deployment are mission-critical; fully testing them on the ground is a challenging endeavor. The 8 meter long deployable arrays flown on two sequential NASA weather satellites were each comprised of three rigid panels almost 2 meters wide. These large panels were deployed by hinges comprised of stacked constant force springs, eddy current dampers, and were restrained through launch by a set of four releasable hold-downs using shape memory alloy release devices. The ground qualification testing of such unwieldy deployable solar arrays, whose design was optimized for orbital operations, proved to be quite challenging and provides numerous lessons learned. A paperwork review and follow-up inspection after hardware storage determined that there were negative torque margins and missing lubricant, this paper will explain how these unexpected issues were overcome. The paper will also provide details on how the hinge subassemblies, the fully-assembled array, and mechanical ground support equipment were subsequently improved and qualified for a follow-on flight with considerably less difficulty. The solar arrays built by Ball Aerospace Corp. for the Suomi National Polar Partnership (S-NPP) satellite and the Joint Polar Satellite System (JPSS-1) satellite (now NOAA-20) were both successfully deployed on-obit and are performing well.

Helfrich, Daniel↗