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NASA NTRS1975

Some properties of Ni-Cu foils and their behavior when heated in hydrogen

Nickel foils of nominal thickness 0.1 and 1 micron have been resistively evaporated onto copper-foil substrates of thickness 25 and 2.5 microns. In depositions in which the pressure was as high as 0.00001 torr, the deposited nickel was not shiny and appeared granular in a 100x microscope. Foils evaporated in higher vacuums were shiny, but became granular if heated to 500 C in oxygen at pressures greater than 0.000005 torr, or in carbon dioxide at pressures greater than 0.0000005 torr. This phenomenon has been interpreted as recrystallization. Foils heated to 500 C at pressures of hydrogen above 0.0003 torr exhibit cracking characteristic of hydrogen embrittlement. The bimetallic foils curled concave toward the nickel during evaporation, consistent with a connected-island form of film growth.

Morrison, R. A.↗

NASA NTRS1984

Bending fatigue of electron-beam-welded foils. Application to a hydrodynamic air bearing in the Chrysler/DOE upgraded automotive gas tubine engine

A hydrodynamic air bearing with a compliment surface is used in the gas generator of an upgraded automotive gas turbine engine. In the prototype design, the compliant surface is a thin foil spot welded at one end to the bearing cartridge. During operation, the foil failed along the line of spot welds which acted as a series of stress concentrators. Because of its higher degree of geometric uniformity, electron beam welding of the foil was selected as an alternative to spot welding. Room temperature bending fatigue tests were conducted to determine the fatigue resistance of the electron beam welded foils. Equations were determined relating cycles to crack initiation and cycles to failure to nominal total strain range. A scaling procedure is presented for estimating the reduction in cyclic life when the foil is at its normal operating temperature of 260 C (500 F).

Saltsman, J. F.↗

NASA NTRS1989

Surface treatment using metal foil liner

A metal foil liner can be used to seal large area surfaces. Characteristics of the two-layer foil liner are discussed. Micrographs for foil-to-foil, foil-to-composite, visible seams, and hidden seams are examined.

Garvey, Ray↗

NASA NTRS1992

H Ly-alpha transmittance of thin foils of C, Si/C, and Al/C for keV particle detectors

A class of instruments designed for remote sensing of space plasmas by measuring energetic neutral atoms (ENA) uses a thin foil as both a signal generator and a light shield. An ENA imager must look directly at the ENA source region, which is also usually an intense source of H Ly-alpha (1216 A) photons. It is desirable to minimize the energy threshold for ENA detectors, at the same time maximizing the blocking of H Ly-alpha. Optimizing filter design to meet these two contrary requirements has led us to measure the transmittance of thin C, Si/C, and Al/C foils at H Ly-alpha. Our results indicate that (1) transmittance of less than 0.0007 can be achieved with 7 micro-g/sq cm Si on 1.7 micro-g/sq cm C; (2) an Si/C composite foil with a thin carbon layer is more effective in blocking UV radiation while having the lowest energy threshold of all the foils measured; and (3) transmittance of Si/C foils of known Si and C thicknesses cannot be accurately predicted, but must be measured.

Drake, V. A.↗

NASA NTRS1992

X-ray scattering measurements from thin foil X-ray mirrors

Thin foil X-ray mirrors are to be used as the reflecting elements in the telescopes of the X-ray satellites Spectrum-X-Gamma (SRG) and ASTRO-D. High resolution X-ray scattering measurements from the Au coated and dip-lacquered Al foils are presented. These were obtained from SRG mirrors positioned in a test quadrant of the telescope structure and from ASTRO-D foils held in a simple fixture. The X-ray data is compared with laser data and other surface structure data such as STM, atomic force microscopy (AFM), TEM, and electron micrography. The data obtained at Cu K-alpha(1), (8.05 keV) from all the mirrors produced on Al foils shows a scatter which limits the obtainable half-power width to above 1.5 arcmin. Mirrors based on electroformed Ni foils, however, show local regions with a factor of 4 better performance, and they are being developed for future applications.

Christensen, F. E.↗

NASA NTRS1993

Liquid hydrogen foil-bearing turbopump

The testing and performance evaluation of a liquid hydrogen turbopump with the rotor supported by foil bearings is discussed. The objectives of the program were to demonstrate the long-life feature of a foil-bearing turbopump and to evaluate its operational characteristics. The demonstration has successfully shown the reliability, long life, and robust nature of foil-bearing turbopumps by operating for long periods of time, with many start and stop cycles and a wide speed range. It has also proven that foil-bearing turbopumps can start without total chilldown of the foil bearing, offering operational simplicity.

Gilbrech, Richard J.↗

NASA NTRS2005

An Oil-Free Thrust Foil Bearing Facility Design, Calibration, and Operation

New testing capabilities are needed in order to foster thrust foil air bearing technology development and aid its transition into future Oil-Free gas turbines. This paper describes a new test apparatus capable of testing thrust foil air bearings up to 100 mm in diameter at speeds to 80,000 rpm and temperatures to 650 C (1200 F). Measured parameters include bearing torque, load capacity, and bearing temperatures. This data will be used for design performance evaluations and for validation of foil bearing models. Preliminary test results demonstrate that the rig is capable of testing thrust foil air bearings under a wide range of conditions which are anticipated in future Oil-Free gas turbines. Torque as a function of speed and temperature corroborates results expected from rudimentary performance models. A number of bearings were intentionally failed with no resultant damage whatsoever to the test rig. Several test conditions (specific speeds and loads) revealed undesirable axial shaft vibrations which have been attributed to the magnetic bearing control system and are under study. Based upon these preliminary results, this test rig will be a valuable tool for thrust foil bearing research, parametric studies and technology development.

Bauman, Steve↗

NASA NTRS2004

Changes in Hardware in Order to Accommodate Compliant Foil Air Bearings of a Larger Size

Compliant foil air bearings are at the forefront of the Oil-Free turbomachinery revolution of supporting gas turbine engines with air lubricated hydrodynamic bearings. Foil air bearings have existed for almost fifty years, yet their commercialization has been confined to relatively small, high-speed systems characterized by low temperatures and loads, such as in air cycle machines, turbocompressors and micro-turbines. Recent breakthroughs in foil air bearing design and solid lubricant coating technology, have caused a resurgence of research towards applying Oil-Free technology to more demanding applications on the scale of small and mid range aircraft gas turbine engines. In order to foster the transition of Oil-Free technology into gas turbine engines, in-house experiments need to be performed on foil air bearings to further the understanding of their complex operating principles. During my internship at NASA Glenn in the summer of 2003, a series of tests were performed to determine the internal temperature profile in a compliant bump- type foil journal air bearing operating at room temperature under various speeds and load conditions. From these tests, a temperature profile was compiled, indicating that the circumferential thermal gradients were negligible. The tests further indicated that both journal rotational speed and radial load are responsible for heat generation with speed playing a more significant role in the magnitude of the temperatures. As a result of the findings from the tests done during the summer of 2003, it was decided that further testing would need to be done, but with a bearing of a larger diameter. The bearing diameter would now be increased from two inches to three inches. All of the currently used testing apparatus was designed specifically for a bearing that was two inches in diameter. Thus, my project for the summer of 2004 was to focus specifically on the scatter shield put around the testing rig while running the bearings. Essentially I was to design a scatter shield that would be able to accommodate the three inch bearing and that would also meet all safety requirements. Furthermore, the new scatter shield also had to house a heater, used for high-speed and temperature testing. Using Solidworks, a computer aided modeling program, I was able to accomplish the task set out for me and designed the new scatter shield. Furthermore, I also guided the fabrication process. As a result of this containment shield being designed, the Oil-Free turbomachinery team now has the ability to test bearings of larger diameters. Finally, it is expected that these tests will provide information useful for the validation of future analytical modeling codes.

Zeszotek, Michelle↗

NASA NTRS2000

System Being Developed to Measure the Rotordynamic Characteristics of Air Foil Bearings

Because of the many possible advantages of oil-free engine operation, interest in using air lubricated foil-bearing technology in advanced oil-free engine concepts has recently increased. The Oil-Free Turbomachinery Program at the NASA Glenn Research Center at Lewis Field has partially driven this recent push for oil-free technology. The program's goal of developing an innovative, practical, oil-free gas turbine engine for aeropropulsion began with the development of NASA's high-temperature solid-lubricant coating, PS304. This coating virtually eliminates the life-limiting wear that occurs during the startup and shutdown of the bearings. With practically unlimited life, foil air bearings are now very attractive to rotating machinery designers for use in turbomachinery. Unfortunately, the current knowledge base of these types of bearings is limited. In particular, the understanding of how these types of bearings contribute to the rotordynamic stability of turbomachinery is insufficient for designers to design with confidence. Recent work in oil-free turbomachinery has concentrated on advancing the understanding of foil bearings. A high-temperature fiber-optic displacement probe system and measurement method were developed to study the effects of speed, load, temperature, and other environmental issues on the stiffness characteristics of air foil bearings. Since high temperature data are to be collected in future testing, the testing method was intentionally simplified to minimize the need for expensive test hardware. The method measures the displacement induced upon a bearing in response to an applied perturbation load. The early results of these studies, which are shown in the accompanying figure, indicate trends in steady state stiffness that suggest stiffness increases with load and decreases with speed. It can be seen, even from these data, that stiffness is not expected to change by orders of magnitude over the normal operating range of most turbomachinery; a promising sign for their eventual integration into oil-free turbomachines. Planned future testing will generate similar plots for stiffness changes with temperature and geometry, as well as damping data. The data collected by this method represent a critical step toward understanding how to successfully apply foil air bearings to future oil-free turbomachinery systems.

Howard, Samuel A.↗

NASA NTRS2005

Analytic Modeling of the Hydrodynamic, Thermal, and Structural Behavior of Foil Thrust Bearings

A simulation and modeling effort is conducted on gas foil thrust bearings. A foil bearing is a self acting hydrodynamic device capable of separating stationary and rotating components of rotating machinery by a film of air or other gaseous lubricant. Although simple in appearance these bearings have proven to be complicated devices in analysis. They are sensitive to fluid structure interaction, use a compressible gas as a lubricant, may not be in the fully continuum range of fluid mechanics, and operate in the range where viscous heat generation is significant. These factors provide a challenge to the simulation and modeling task. The Reynolds equation with the addition of Knudsen number effects due to thin film thicknesses is used to simulate the hydrodynamics. The energy equation is manipulated to simulate the temperature field of the lubricant film and combined with the ideal gas relationship, provides density field input to the Reynolds equation. Heat transfer between the lubricant and the surroundings is also modeled. The structural deformations of the bearing are modeled with a single partial differential equation. The equation models the top foil as a thin, bending dominated membrane whose deflections are governed by the biharmonic equation. A linear superposition of hydrodynamic load and compliant foundation reaction is included. The stiffness of the compliant foundation is modeled as a distributed stiffness that supports the top foil. The system of governing equations is solved numerically by a computer program written in the Mathematica computing environment. Representative calculations and comparisons with experimental results are included for a generation I gas foil thrust bearing.

Bruckner, Robert J.↗

NASA NTRS2006

Gas Foil Bearings for Space Propulsion Nuclear Electric Power Generation

The choice of power conversion technology is critical in directing the design of a space vehicle for the future NASA mission to Mars. One candidate design consists of a foil bearing supported turbo alternator driven by a helium-xenon gas mixture heated by a nuclear reactor. The system is a closed-loop, meaning there is a constant volume of process fluid that is sealed from the environment. Therefore, foil bearings are proposed due to their ability to use the process gas as a lubricant. As such, the rotor dynamics of a foil bearing supported rotor is an important factor in the eventual design. The current work describes a rotor dynamic analysis to assess the viability of such a system. A brief technology background, assumptions, analyses, and conclusions are discussed in this report. The results indicate that a foil bearing supported turbo alternator is possible, although more work will be needed to gain knowledge about foil bearing behavior in helium-xenon gas.

Howard, Samuel A.↗

NASA NTRS2006

A Preliminary Foil Gas Bearing Performance Map

Recent breakthrough improvements in foil gas bearing load capacity, high temperature tribological coatings and computer based modeling have enabled the development of increasingly larger and more advanced Oil-Free Turbomachinery systems. Successful integration of foil gas bearings into turbomachinery requires a step wise approach that includes conceptual design and feasibility studies, bearing testing, and rotor testing prior to full scale system level demonstrations. Unfortunately, the current level of understanding of foil gas bearings and especially their tribological behavior is often insufficient to avoid developmental problems thereby hampering commercialization of new applications. In this paper, a new approach loosely based upon accepted hydrodynamic theory, is developed which results in a "Foil Gas Bearing Performance Map" to guide the integration process. This performance map, which resembles a Stribeck curve for bearing friction, is useful in describing bearing operating regimes, performance safety margins, the effects of load on performance and limiting factors for foil gas bearings.

DellaCorte, Christopher↗

NASA NTRS2008

Misalignment in Gas Foil Journal Bearings: An Experimental Study

As gas foil journal bearings become more prevalent in production machines, such as small gas turbine propulsion systems and microturbines, system-level performance issues must be identified and quantified in order to provide for successful design practices. Several examples of system-level design parameters that are not fully understood in foil bearing systems are thermal management schemes, alignment requirements, balance requirements, thrust load balancing, and others. In order to address some of these deficiencies and begin to develop guidelines, this paper presents a preliminary experimental investigation of the misalignment tolerance of gas foil journal bearing systems. Using a notional gas foil bearing supported rotor and a laser-based shaft alignment system, increasing levels of misalignment are imparted to the bearing supports while monitoring temperature at the bearing edges. The amount of misalignment that induces bearing failure is identified and compared to other conventional bearing types such as cylindrical roller bearings and angular contact ball bearings. Additionally, the dynamic response of the rotor indicates that the gas foil bearing force coefficients may be affected by misalignment.

Howard, Samuel A.↗

NASA NTRS2010

A New Analysis Tool Assessment for Rotordynamic Modeling of Gas Foil Bearings

Gas foil bearings offer several advantages over traditional bearing types that make them attractive for use in high-speed turbomachinery. They can operate at very high temperatures, require no lubrication supply (oil pumps, seals, etc.), exhibit very long life with no maintenance, and once operating airborne, have very low power loss. The use of gas foil bearings in high-speed turbomachinery has been accelerating in recent years, although the pace has been slow. One of the contributing factors to the slow growth has been a lack of analysis tools, benchmarked to measurements, to predict gas foil bearing behavior in rotating machinery. To address this shortcoming, NASA Glenn Research Center (GRC) has supported the development of analytical tools to predict gas foil bearing performance. One of the codes has the capability to predict rotordynamic coefficients, power loss, film thickness, structural deformation, and more. The current paper presents an assessment of the predictive capability of the code, named XLGFBTH (Texas A&M University). A test rig at GRC is used as a simulated case study to compare rotordynamic analysis using output from the code to actual rotor response as measured in the test rig. The test rig rotor is supported on two gas foil journal bearings manufactured at GRC, with all pertinent geometry disclosed. The resulting comparison shows that the rotordynamic coefficients calculated using XLGFBTH represent the dynamics of the system reasonably well, especially as they pertain to predicting critical speeds.

Howard, Samuel A.↗

NASA NTRS1970

The dynamic characteristics of a turbo-rotor simulator supported on gas-lubricated foil bearings. Part 1: Response to rotating imbalance and unidirectional excitation

A sixteen-inch rotor, weighing approximately twenty-one pounds, was supported by air-lubricated foil bearings. In physical size and in mass distribution, the rotor closely matched that of an experimental Brayton cycle turboalternator unit. The rotor was stable in both vertical horizontal attitudes at speeds up to 50,000 rpm. A detailed description of the experimental apparatus and of the foil bearing design are given. The paper contains data on response of the rotor to rotating imbalance, symmetric and asymmetric, and to excitation by means of a vibrator (shake table). It is concluded that the gas-lubricated foil bearing suspension is free from fractional frequency whirl and suffers no loss of load capacity when excited at frequency equal to half the rotational speed. In contrast to rigid gas bearings, the foil bearing imposes no stringent requirements with respect to dimensional tolerances, cleanliness, or limitations of journal motion within the narrow confines of bearing clearance.

Licht, L.↗

NASA NTRS1973

Gas-lubricated foil bearings for high speed turboalternator - Construction and performance

Foil bearings were designed and fabricated to replace pivoted-shoe journal bearings in a Brayton cycle turboalternator, within space limitations and constraints imposed by the existing machine. The foil bearings were integrated into a unified assembly with the rotor, housing, seals, and gimbal-mounted thrust bearing, without changes and modifications of machine components other than the journal bearings. The gas-lubricated foil bearings, which require no external pressure-source, furnished a stable support for a 21.9 pound rotor in the vertical attitude at speeds to 43,200 rpm. Excellent wipe-wear characteristics permitted well over 1000 start-stop cycles, without deterioration of performance in the entire speed range. The paper reviews salient aspects of design, fabrication, and performance. An account is given of rotor dynamics during starting, stopping, and traversing the region of resonances. The state of journal and foil surfaces is examined following intensive start-stop cycling and high-speed runs over extended periods of time.

Licht, L.↗

NASA NTRS1974

Polarization and collision-induced coherence in the beam-foil light source

Monatomic systems were excited by the beam-foil method in order to re-examine the possibility that a particular magnetic substate was preferentially populated. O II, Ar II and He I levels were used. The results reveal that: (1) with a tilted foil substantial polarization (up to 15%) may be achieved, (2) the polarization is due to the foil, (3) the foil induces coherence among Zeeman substates with the appearance of quantum beats among these substates and that their coherence is due to the externally applied magnetic field perpendicular to the beam direction, and (4) the angular momentum of the emitted photon is perpendicular to the ion velocity. The possibility for detecting separate effects of alignment and polarization is noted.

Liu, C. H.↗

NASA NTRS1977

The transonic multi-foil Augmentor-Wing

The paper describes the development of a transonic blown multi-foil Augmentor-Wing airfoil section that has a thickness/chord (t/c) value of 0.18. In comparison with an unblown single-foil supercritical section of the same overall t/c the new multi-foil section is characterized by an increased drag rise Mach number, increased buffet boundaries, and a reduction in 'effective' drag due to blowing. Potential advantages of the Augmentor-Wing are considered and the testing of three high-speed models in a trisonic pressurized wind tunnel (possessing a two-dimensional transonic insert) is discussed. The data indicate that a very thick wing is feasible since separations toward the rear of the main foil can be controlled both by shroud location and augmentor blowing.

Farbridge, J. E.↗