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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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NASA NTRS1974

Testing a satellite automatic nutation control system

Testing of a particular nutation control system for the synchronous meteorological satellite (SMS) is described. The test method and principles are applicable to nutation angle control for other satellites with similar requirements. During its ascent to synchronous orbit, a spacecraft like the SMS spins about its minimum-moment-of-inertia axis. An uncontrolled spacecraft in this state is unstable because torques due to fuel motion increase the nutation angle. However, the SMS is equipped with an automatic nutation control (ANC) system which will keep the nutation angle close to zero. Because correct operation of this system is critical to mission success, it was tested on an air-bearing table. The ANC system was mounted on the three-axis air-bearing table which was scaled to the SMS and equipped with appropriate sensors and thrusters. The table was spun up in an altitude chamber and nutation induced so that table motion simulated spacecraft motion. The ANC system was used to reduce the nutation angle. This dynamic test of the ANC system met all its objectives and provided confidence that the ANC system will control the SMS nutation angle.

Hrasiar, J. A.↗
NASA NTRS2004

Friction and Wear Characteristics of Cu-4Al Foil Bearing Coating at 25 and 650 degree C

The friction and wear performance of a Cu-4Al top foil coating has been investigated in Generation I foil air bearings. The copper alloy was applied by a novel deposition technique (ion diffusion) and the journal was coated with PS304, a plasma spray deposited high temperature composite solid lubricant coating. The ion diffusion coating process deposits a desirable smooth layer compared to other methods like cathodic arc deposition. The tribological performance of bearings with and without Cu-4Al foil coatings were evaluated through start-stop tests on an air bearing test rig at 25 and 650 C. The results indicate that the Cu-4Al assists during the initial break-in period, gives more stable friction performance with respect to temperature, and appears to prevent top foil wear at high temperature. The measured load capacity coefficient was 0.5, which was comparable to earlier testing of more advanced design Generation III bearings coated with standard cathodic arc deposited Cu-4Al. However, further studies are needed to determine if deeper penetration of the copper alloy into the foil would help make the transition in friction behavior from contact with the Cu-4Al coated foil to contact with the base foil material more gradual. Also, future work is recommended to assess the performance of ion diffusion coatings with different Cu-based alloy compositions and to investigate the effect the coating has on the elastic modulus of the foil material.

Stanford, Malcolm K.↗
NASA NTRS2004

The Formation Control Testbed

This paper describes the design and construction of the Formation Control Testbed. The FCT consists of three robots navigating on an air bearing floor, propelled by cold gas thrusters. Each robot contains an attitude platform supported on a spherical air bearing which provides three rotational degrees of freedom. The sixth degree of freedom, vertical translation, will be provided by a powered vertical stage, actively controlled to provide a simulated zero-g environment for the attitude platform.

Singh, Gurkirpal↗
NASA NTRS2007

Oil-Free Rotor Support Technologies for an Optimized Helicopter Propulsion System

An optimized rotorcraft propulsion system incorporating a foil air bearing supported Oil-Free engine coupled to a high power density gearbox using high viscosity gear oil is explored. Foil air bearings have adequate load capacity and temperature capability for the highspeed gas generator shaft of a rotorcraft engine. Managing the axial loads of the power turbine shaft (low speed spool) will likely require thrust load support from the gearbox through a suitable coupling or other design. Employing specially formulated, high viscosity gear oil for the transmission can yield significant improvements (approx. 2X) in allowable gear loading. Though a completely new propulsion system design is needed to implement such a system, improved performance is possible.

DellaCorte, Christopher↗
NASA NTRS1999

High-Temperature Solid Lubricants Developed by NASA Lewis Offer Virtually "Unlimited Life" for Oil-Free Turbomachinery

The NASA Lewis Research Center is capitalizing on breakthroughs in foil air bearing performance, tribological coatings, and computer analyses to formulate the Oil-free Turbomachinery Program. The program s long-term goal is to develop an innovative, yet practical, oil-free aeropropulsion gas turbine engine that floats on advanced air bearings. This type of engine would operate at higher speeds and temperatures with lower weight and friction than conventional oil-lubricated engines. During startup and shutdown, solid lubricant coatings are required to prevent wear in such engines before the self-generating air-lubrication film develops. NASA s Tribology Branch has created PS304, a chrome-oxide-based plasma spray coating specifically tailored for shafts run against foil bearings. PS304 contains silver and barium fluoride/calcium fluoride eutectic (BaF2/CaF2) lubricant additives that, together, provide lubrication from cold start temperatures to over 650 C, the maximum use temperature for foil bearings. Recent lab tests show that bearings lubricated with PS304 survive over 100 000 start-stop cycles without experiencing any degradation in performance due to wear. The accompanying photograph shows a test bearing after it was run at 650 C. The rubbing process created a "polished" surface that enhances bearing load capacity.

DellaCorte, Christopher↗
NASA NTRS2001

Oil-Free Turbomachinery Being Developed

NASA and the Army Research Laboratory (ARL) along with industry and university researchers, are developing Oil-Free technology that will have a revolutionary impact on turbomachinery systems used in commercial and military applications. System studies have shown that eliminating an engine's oil system can yield significant savings in weight, maintenance, and operational costs. The Oil-Free technology (foil air bearings, high-temperature coatings, and advanced modeling) is being developed to eliminate the need for oil lubrication systems on high-speed turbomachinery such as turbochargers and gas turbine engines that are used in aircraft propulsion systems. The Oil-Free technology is enabled by recent breakthroughs in foil bearing load capacity, solid lubricant coatings, and computer-based analytical modeling. During the past fiscal year, a U.S. patent was awarded for the NASA PS300 solid lubricant coating, which was developed at the NASA Glenn Research Center. PS300 has enabled the successful operation of foil air bearings to temperatures over 650 C and has resulted in wear lives in excess of 100,000 start/stop cycles. This leapfrog improvement in performance over conventional solid lubricants (limited to 300 C) creates new application opportunities for high-speed, high-temperature Oil-Free gas turbine engines. On the basis of this break-through coating technology and the world's first successful demonstration of an Oil-Free turbocharger in fiscal year 1999, industry is partnering with NASA on a 3-year project to demonstrate a small, Oil-Free turbofan engine for aeropropulsion.

DellaCorte, Christopher↗
NASA NTRS2018

Developed AprilNav, an Indoor Navigation and Localization System for Autonomous Testing of Electric Sail Dynamics

An electrostatic sail (E-sail) is a new type of propulsion which harnesses the Sun's solar wind to propel a spacecraft. Voyager I took about 40 years to reach interstellar space using solid rocket propellant, whereas electrostatic sails can travel the same distance in 6-10 years by using small but constant acceleration. As part of Marshall Space Flight Center's (MSFC) Space Systems Dept. and Advanced Concepts Office, we are continuing research for the HERTS (Heliopause Electrostatic Rapid Transit System) E-sail project. Previous researchers developed a Nano Air-bearing Simulator (NAS) prototype for initial testing of E-sails; this prototype was properly documented in CAD (Computer-Aided Drafting) in order to build a second improved NAS. MSFC's Robotic Lab (Flat Floor) allows for 2-dimensional simulations of spacecraft dynamics by attaching air bearings to a system. An indoor navigation system AprilNav, was developed and has been implemented on the ceiling of the flat floor for localization and autonomous testing of the two bearing-equipped NAS. With two NAS, tether dynamics between the two simulators as well as steering control algorithms are being tested on the flat floor using AprilNav.

Schuler, Tristan↗
NASA NTRS2003

Industry Needs Fulfilled by Patented NASA PS300 Solid Lubricant Technology

In 1999, the NASA Glenn Research Center was awarded a patent (#5866518) for a new high-temperature solid lubricant coating material, PS300. A combination of wear-resistant metals and ceramics with solid lubricant additives, PS300 reduces friction and wear in sliding contacts from below ambient to over 650 C. This lubricant is an outgrowth of over three decades of high-temperature tribological research and was specifically developed as a shaft lubricant to protect foil air bearings used in Oil-Free turbomachinery, like gas turbines. Foil bearings are lubricated by air at high speeds but experience sliding and wear during initial startup and shut down when a lubricating film of air has not yet developed. PS300 shaft coatings have successfully lubricated foil bearings for over 100 000 cycles without wearing out.

DellaCorte, Christopher↗
NASA NTRS2002

Heat Treatment Used to Strengthen Enabling Coating Technology for Oil-Free Turbomachinery

The PS304 high-temperature solid lubricant coating is a key enabling technology for Oil- Free turbomachinery propulsion and power systems. Breakthroughs in the performance of advanced foil air bearings and improvements in computer-based finite element modeling techniques are the key technologies enabling the development of Oil-Free aircraft engines being pursued by the Oil-Free Turbomachinery team at the NASA Glenn Research Center. PS304 is a plasma spray coating applied to the surface of shafts operating against foil air bearings or in any other component requiring solid lubrication at high temperatures, where conventional materials such as graphite cannot function.

Edmonds, Brian J.↗
NASA NTRS1992

Digital active material processing platform effort (DAMPER), SBIR phase 2

Applied Technology Associates, Inc., (ATA) has demonstrated that inertial actuation can be employed effectively in digital, active vibration isolation systems. Inertial actuation involves the use of momentum exchange to produce corrective forces which act directly on the payload being actively isolated. In a typical active vibration isolation system, accelerometers are used to measure the inertial motion of the payload. The signals from the accelerometers are then used to calculate the corrective forces required to counteract, or 'cancel out' the payload motion. Active vibration isolation is common technology, but the use of inertial actuation in such systems is novel, and is the focus of the DAMPER project. A May 1991 report was completed which documented the successful demonstration of inertial actuation, employed in the control of vibration in a single axis. In the 1 degree-of-freedom (1DOF) experiment a set of air bearing rails was used to suspend the payload, simulating a microgravity environment in a single horizontal axis. Digital Signal Processor (DSP) technology was used to calculate in real time, the control law between the accelerometer signals and the inertial actuators. The data obtained from this experiment verified that as much as 20 dB of rejection could be realized by this type of system. A discussion is included of recent tests performed in which vibrations were actively controlled in three axes simultaneously. In the three degree-of-freedom (3DOF) system, the air bearings were designed in such a way that the payload is free to rotate about the azimuth axis, as well as translate in the two horizontal directions. The actuator developed for the DAMPER project has applications beyond payload isolation, including structural damping and source vibration isolation. This report includes a brief discussion of these applications, as well as a commercialization plan for the actuator.

Blackburn, John↗
NASA NTRS2006

Thermal Management Techniques for Oil-Free Turbomachinery Systems

Tests were performed to evaluate three different methods of utilizing air to provide thermal management control for compliant journal foil air bearings. The effectiveness of the methods was based on bearing bulk temperature and axial thermal gradient reductions during air delivery. The first method utilized direct impingement of air on the inner surface of a hollow test journal during operation. The second, less indirect method achieved heat removal by blowing air inside the test journal to simulate air flowing axially through a hollow, rotating shaft. The third method emulated the most common approach to removing heat by forcing air axially through the bearing s support structure. Internal bearing temperatures were measured with three, type K thermocouples embedded in the bearing that measured general internal temperatures and axial thermal gradients. Testing was performed in a 1 atm, 260 C ambient environment with the bearing operating at 60 krpm and supporting a load of 222 N. Air volumetric flows of 0.06, 0.11, and 0.17 cubic meters per minute at approximately 150 to 200 C were used. The tests indicate that all three methods provide thermal management but at different levels of effectiveness. Axial cooling of the bearing support structure had a greater effect on bulk temperature for each air flow and demonstrated that the thermal gradients could be influenced by the directionality of the air flow. Direct air impingement on the journal's inside surface provided uniform reductions in both bulk temperature and thermal gradients. Similar to the direct method, indirect journal cooling had a uniform cooling effect on both bulk temperatures and thermal gradients but was the least effective of the three methods.

Radil, Kevin↗
NASA NTRS1980

Friction and wear results from sputter-deposited chrome oxide with and without nichrome metallic binders and interlayers

Friction and wear tests were conducted on optimized sputtered Cr2O3 and Cr2O3 with metallic binder coatings. The coatings were applied on the bearing surface of journal foil air bearings and were tested against chrome-carbide-coated journal surfaces. The objective of the study was to develop a coating system which would withstand 9000 start-stops and high-speed rubs (maximum acceleration, 100 gs) in temperatures ranging from room temperature to 650 C. The Cr2O3 coating completed the test sequence and the coating consisting of Cr2O3 with metallic binders completed 3000 start-stops. The coefficient of friction of the coatings at 650 C was found to be about half that at room temperature. It was concluded, therefore, that the coatings should perform much better in a high temperature environment alone. The decrease in friction at high temperature is attributed to oxidation and interactions of the coatings and substrates at the interface temperature.

Bhushan, B.↗
NASA NTRS1989

Dynamic Torque Calibration Unit

Proposed dynamic torque calibration unit (DTCU) measures torque in rotary actuator components such as motors, bearings, gear trains, and flex couplings. Unique because designed specifically for testing components under low rates. Measures torque in device under test during controlled steady rotation or oscillation. Rotor oriented vertically, supported by upper angular-contact bearing and lower radial-contact bearing that floats axially to prevent thermal expansion from loading bearings. High-load capacity air bearing available to replace ball bearings when higher load capacity or reduction in rate noise required.

Agronin, Michael L.↗
NASA NTRS2001

Dynamic Stiffness and Damping Characteristics of a High-Temperature Air Foil Journal Bearing

Using a high-temperature optically based displacement measurement system, a foil air bearing's stiffness and damping characteristics were experimentally determined. Results were obtained over a range of modified Sommerfeld Number from 1.5E6 to 1.5E7, and at temperatures from 25 to 538 C. An Experimental procedure was developed comparing the error in two curve fitting functions to reveal different modes of physical behavior throughout the operating domain. The maximum change in dimensionless stiffness was 3.0E-2 to 6.5E-2 over the Sommerfeld Number range tested. Stiffness decreased with temperature by as much as a factor of two from 25 to 538 C. Dimensionless damping was a stronger function of Sommerfeld Number ranging from 20 to 300. The temperature effect on damping being more qualitative, showed the damping mechanism shifted from viscous type damping to frictional type as temperature increased.

Howard, Samuel A.↗
NASA NTRS1976

NASA's 91-cm. airborne telescope

The Gerard P. Kuiper Airborne Observatory (KAO), commissioned in May 1975, is the result of the multi-year NASA program of infrared observations from high-flying aircraft. The KAO is a highly modified Lockheed C-141 jet transport, equipped with a 91-cm bent-Cassegrain telescope, as an international facility for research in infrared astronomy. To minimize the effects of aircraft vibration, the telescope is mounted on four pneumatic shock absorbers, and the entire assembly is balanced on the side of a spherical compressed-air bearing, containing a 0.018 mm-thick air film under a pressure of 19 atmospheres. The use of the KAO is not limited to infrared research, its total observable wavelength band extending from the near UV (3000 A) to the millimeter region. Design and technical characteristics of the telescope are discussed, including the image stabilization and target acquisition systems, as well as observational results obtained during the first year of the KAO operation.

Cameron, R. M.↗
NASA NTRSDate not supplied

Countermeasures for Mitigation of Sensorimotor Decrements Following Head-Down Bed Rest

BACKGROUND Decrements in functional performance of tasks requiring postural and locomotor control remain common among crewmembers returning to Earth after6months on the International Space Station (ISS). These impairments will presumably be exacerbated after longer exploration-class missions with fewer exercise hardware options. Our recent studies suggest that an in-flight proprioceptive countermeasure may keep the proprioceptive system tuned to respond to upright balance challenges in a gravitational environment. Before testing a proprioceptive countermeasure in-flight, we must conduct an initial proof-of-concept study to determine its potential efficacy in a controlled unloading analog setting. OBJECTIVES We will determine if proprioceptive training during 60 days of 6° head down bed rest (HDBR) mitigates declines in functional task performance. We consider it critical to characterize the interaction between proprioceptive training and exercise. Thus, we will compare 3groupsof subjects(N=12 each): a proprioceptive training group, an exercise plus proprioceptive training group, and a control group(i.e. no training or exercise).The primary outcome measure will be the well-established and operationally relevant seat egress and walk test (also referred to as the functional mobility test)performed before and after HDBR. Other functional tests will also represent high priority exploration mission tasks that require high demand for dynamic control of postural stability. Additional measures will be used to identify the key physiological factors contributing to countermeasure benefits. COUNTERMEASURE METHODS We will use a ground version of our countermeasure to test the efficacy of proprioceptive training while maintaining HDBR constraints. Subjects will remain in the horizontal supine position on a sled that moves freely on air-bearings, similar to a puck on an air hockey table. Subjects will be loaded axially up to one full body weight via lateral cable pulleys towards their feet on an instrumented tilt board using a harness and weights system. Visual feedback of board tilt will be used to guide subjects while they make active tilts. Exercise and proprioceptive training prescriptions will represent those expected to be implemented during exploration spaceflight missions(e.g.20-minute proprioceptive training sessions3 times per week). RELEVANCE The deliverable from this project will be a proof-of-concept countermeasure design that has been fully assessed for efficacy in a spaceflight analog. The findings and lessons learned from this study will be translated for validation of this countermeasure on the ISS. An effective countermeasure will be added to the suite of operationally implemented in-flight sensorimotor countermeasures.

T R Macaulay↗