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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 109 records · Page 6

Integrity testing of brush seal in a T-700 engine

A split-ring brush seal was fabricated, installed between two labyrinth-honeycomb shroud seals, and tested in the fourth-stage turbine of a T-700 engine. The annealed Haynes 25 bristles rubbed directly against the nonconditioned, irregular Rene 80 turbine blade shroud surface. A total of 21 hr of cyclic and steady-state data were taken with surface speeds of 335 m/s (1100 ft/s) and shroud temperatures to 620 C (1150 F). Wear appeared to be rapid initially, with an orange flash of hot brush fragments during the first engine startup, to minimal after 10 hr of operation. The brush survived the testing but experienced some bristle pullouts and severe bristle wear; some turbine interface wear and possible material transfer was noted. Future design concerns center on tribological behavior at the interface with or without lubricants.

Hendricks, Robert C.↗

Air Force brush seal programs

Aggressive pursuit of increased performance in gas turbine engines is driving the thermodynamic cycle to higher pressure ratios, bypass ratios, and turbine inlet temperatures. As these parameters increase, internal air system and resultant thermodynamic cycle losses increase. This conflict of reducing internal airflows while increasing thermodynamic efficiency and performance is putting more emphasis on improvements to the internal flow system. One improvement that has been and continues to be pursued by the Air Force for both man-rated and expendable turbine engine applications is the brush seal. This presentation briefly describes both past and current brush seal research and development programs and gives a summary of demonstrator and developmental engine testing of brush seals.

Dowler, Connie↗

Current developments in brush seals

The objective of the brush seal development program is to develop a comprehensive design methodology for brush seals using application requirements from engine manufacturers and experimental characterization of seal design and tribological pairs. The goals are to substantially lower leakage compared to labyrinth seals, seal life consistent with man-rated mission requirements, to investigate single and multiple staged brush seals, temperature up to 1200 F and surface speed up to 900 fps, and pressure drop across the seal of 50 psid. Test results are presented in viewgraph format.

Loewenthal, Bob↗

Relative performance comparison between baseline labyrinth and dual-brush compressor discharge seals in a T-700 engine test

In separate series of T-700 engine tests, direct comparisons were made between the forward-facing labyrinth and dual-brush compressor discharge seals. Compressor speeds to 43,000 rpm, surface speeds to 160 m/s (530 ft/s), pressures to 1 MPa (145 psi), and temperatures to 680 K (765 F) characterized these tests. The wear estimate for 40 hr of engine operations was less than 0.025 mm (0.001 in.) of the Haynes 25 alloy bristles running against a chromium-oxide-coated rub runner. The pressure drops were higher for the dual-brush than for the forward-facing labyrinth seal, implying better seal characteristics and engine performance for the brush seal. Modification of the secondary flow path requires that changes in cooling air and engine dynamics be accounted for.

Hendricks, Robert C.↗

A New Tribological Test for Candidate Brush Seal Materials Evaluation

A new tribological test for candidate brush seal materials evaluation has been developed. The sliding contact between the brush seal wires and their mating counterface journal is simulated by testing a small tuft of wire against the outside diameter of a high speed rotating shaft. The test configuration is similar to a standard block on ring geometry. The new tester provides the capability to measure both the friction and wear of candidate wire and counterface materials under controlled loading conditions in the gram to kilogram range. A wide test condition latitude of speeds (1 to 27 m/s), temperatures (25 to 700 C), and loads (0.5 to 10 N) enables the simulation of many of the important tribological parameters found in turbine engine brush seals. This paper describes the new test rig and specimen configuration and presents initial data for candidate seal materials comparing tuft test results and wear surface morphology to field tested seal components.

Fellenstein, James A.↗

High temperature brush seal tuft testing of metallic bristles versus chrome carbide

The tribology of brush seals is of considerable interest to turbine engine designers because bristle wear continues to limit long term seal performance and life. To provide better materials characterization and foster the development of improved seals, NASA Lewis has developed a brush seal tuft tester. In this test, a 'paintbrush' sample tuft is loaded under constant contact pressure against the outside diameter of a rotating journal. With this configuration a direct measurement of load and friction is made. Accurate wear rate measurements are possible due to the known contact pressure. Previously reported baseline research using this facility showed good data repeatability and wear morphology similar to published seal data. This paper extends and expands the database for candidate brush seal materials. A series of tuft tests were completed to evaluate the performance of five high temperature superalloy wires sliding against plasma sprayed nichrome-bonded chrome carbide. Wire materials were either nickel-chrome or cobalt-chrome based superalloys. Good corroboration of the tuft results with dynamic seal rig tests was observed; giving additional confidence in the tuft test as a screening and development tool.

Fellenstein, James A.↗

High Temperature Brush Seal Tuft Testing of Selected Nickel-Chrome and Cobalt-Chrome Superalloys

The tribology of brush seals is of considerable interest to turbine engine designers because bristle wear continues to limit long term seal performance and life. To provide better materials characterization and foster the development of improved seals, NASA Lewis has developed a brush seal tuft tester. In this test, a 'paintbrush' sample tuft is loaded under constant contact pressure against the outside diameter of a rotating journal. With this configuration, load and friction are directly measured and accurate wear measurements are possible. Previously reported research using this facility showed excellent data repeatability and wear morphology similar to published seal data and dynamic rig tests. This paper is an update of the ongoing research into the tribology of brush seals. The effects of wire materials processing on seal wear and the tribological results for three journal coatings are discussed. Included in the materials processing were two nickel-chrome superalloys each processed to two different yield strengths. The results suggest that seal wear is dependent more on material composition than processing conditions.

Fellenstein, James A.↗

"Long life" DC brush motor for use on the Mars surveyor program

DC brush motors have several qualities which make them very attractive for space flight applications. Their mechanical commutation is simple and lightweight, requiring no external sensing and control in order to function properly. They are extremely efficient in converting electrical energy into mechanical energy. Efficiencies over 80% are not uncommon, resulting in high power throughput to weight ratios. However, the inherent unreliability and short life of sliding electrical contacts, especially in vacuum, have driven previous programs to utilize complex brushless DC or the less efficient stepper motors. The Mars Surveyor Program (MSP'98) and the Shuttle Radar Topography Mission (SRTM) have developed a reliable "long life" brush type DC motor for operation in low temperature, low pressure CO2 and N2, utilizing silver-graphite brushes. The original intent was to utilize this same motor for SRTM's space operation, but the results thus far have been unsatisfactory in vacuum. This paper describes the design, test, and results of this development.

Braun, David↗

LM2500+ Brush Seal Case Study

The LM2500+ industrial aeroderivative gas turbine, a 25% enhanced power derivative of the LM2500 gas turbine, recently completed its development test program during the period 5/96 - 10/96. Early in the engine program a Quality Function Deployment (QFD) process was used to determine customer needs for this project.The feedback obtained from the QFD process showed without doubt that gas turbine customers now emphasize product reliability and availability at the top of their needs. One area of development on the LM2500+ was to investigate the use of a brush seal as a means to reduce undesirable turbine cooling leakages within the turbine mid frame in order to enhance part life. This presentation presents a case study on the factors that went into evaluating a brush seal during engine test, test results, and the ultimate decision not to implement the brush seal for cost and other reasons.

Haaser, Fred G.↗

An Overview of Non-Metallic Brush Seal Technology

Non-metallic brush seals are ultra-low flow sealing elements ideal for low pressure differentials (<30 psid) and low temperature (typically <300 degF) applications. The compliant bristle pack of a non-metallic brush seal is advantageous in terms of sealing capability during transients. However, if not designed properly, the bristle pack compliance can be detrimental to the performance of the seal. GE GLobal Research has investigated the stiffness and heat generation properties of non-metallic brush seals made from Kevlar and Carbon Fiber. The presentation will review the progress made on the design points of the seals, as well as highlight some current commercial applications of the technology.

Ruggiero, Eric J.↗

Development of the Upgraded DC Brush Gear Motor for Spacebus Platforms

The obsolescence of materials and processes used in the manufacture of traditional DC brush gear motors has necessitated the development of an upgraded DC brush gear motor (UBGM). The current traditional DC brush gear motor (BGM) design was evaluated using Six-Sigma process to identify potential design and production process improvements. The development effort resulted in a qualified UBGM design which improved manufacturability and reduced production costs. Using Six-Sigma processes and incorporating lessons learned during the development process also improved motor performance for UBGM making it a more viable option for future use as a deployment mechanism in space flight applications.

Berning, Robert H.↗

Brushing Your Spacecrafts Teeth: A Review of Biological Reduction Processes for Planetary Protection Missions

Much like keeping your teeth clean, where you brush away biofilms that your dentist calls "plaque," there are various methods to clean spaceflight hardware of biological contamination, known as biological reduction processes. Different approaches clean your hardware's "teeth" in different ways and with different levels of effectiveness. We know that brushing at home with a simple toothbrush is convenient and has a different level of impact vs. getting your teeth cleaned at the dentist. In the same way, there are some approaches to biological reduction that may require simple tools or more complex implementation approaches (think about sonicating or just soaking your dentures, vs. brushing them). There are also some that are more effective for different degrees of cleanliness and still some that have materials compatibility concerns. In this article, we review known and NASA-certified approaches for biological reduction, pointing out materials compatibility concerns and areas where additional research is needed.

Pugel, D. E. (Betsy)↗

Brushing Your Spacecrafts Teeth: A Review of Biological Reduction Processes for Planetary Protection Missions

Much like keeping your teeth clean, where you brush away biofilms that your dentist calls plaque, there are various methods to clean spaceflight hardware of biological contamination, known as biological reduction processes. Different approaches clean your hardwares teeth in different ways and with different levels of effectiveness. We know that brushing at home with a simple toothbrush is convenient and has a different level of impact vs. getting your teeth cleaned at the dentist. In the same way, there are some approaches to biological reduction that may require simple tools or more complex implementation approaches (think about sonicating or just soaking your dentures, vs. brushing them). There are also some that are more effective for different degrees of cleanliness and still some that have materials compatibility concerns. In this article, we review known and NASA-certified approaches for biological reduction, pointing out materials compatibility concerns and areas where additional research is needed.

Pugel, D.E. (Betsy)↗

A micrometeorological flux perspective on brush management in a shrub-encroached Sonoran Desert grassland

Woody plant encroachment typically limits the forage productivity of managed rangelands and alters a panoply of semiarid ecosystem processes and services. Intervention strategies to reduce woody plant abundance, collectively termed “brush management”, often lack observations to quantify and interpret changes in ecosystem processes. Furthermore, comparative studies between treated and untreated areas should account for heterogeneity since plant composition, microclimate, topoedaphic factors, and historical land use can substantially vary over short distances in drylands. Here, in this work, we quantify ecosystem responses to brush management after a single aerial herbicide application on an 18 hectare shrub-encroached grassland (savanna) in southern Arizona, USA. We conducted a pre- and post-treatment comparison of a flux tower site in the treated area with that of a tower in a nearby control site. The comparison, spanning a seven year period, included: (1) ground, airborne, and satellite-based measurements of vegetation structure, and (2) eddy covariance measurements. The herbicide treatment defoliated the dominant shrub (velvet mesquite, Prosopis velutina) and led to a temporary reduction in summer greening, but full foliar recovery occurred within two years. Contrary to expectations, perennial grass cover decreased and bare soil cover increased on the treated site. Relative amounts of evapotranspiration were reduced, while carbon uptake increased during the 2 year post-treatment period at the treated site due to a higher water use efficiency in the following spring. During mesquite recovery, carbon uptake was enhanced by higher gross primary productivity and accompanied by a decrease in ecosystem respiration relative to the untreated site. Mesquite recovery was facilitated by access to deep soil water, carbohydrate reserves in rooting systems, and a lower competition from reduced perennial grass cover.

54 ENVIRONMENTAL SCIENCES↗

Grafting-To and From for Multiplexed Chemical-Warfare-Agent Responsive Polymer Brushes

Surface-tethered polymers have important applications in functional polymer coatings, particularly for the development of chemically responsive surfaces. Here, we combined the traditional grafting-to and grafting-from methods to create a new surface grafting strategy, termed grafting-to and from, using surface-initiated ring-opening metathesis polymerization (SI-ROMP). In this method, poly(pentafluorophenyl methacrylate) is grafted to an amine terminated surface. Surplus reactive esters after reaction with surface amines render this polymer a connecting or tie layer that can be further reacted to provide dense ROMP initiation sites. This amplification of grafting sites results in thick and environmentally stable polymer brushes upon SI-ROMP. With the goal of developing polymer-grafted breathable membranes that autonomously react to multiple chemical warfare agents (CWAs), we demonstrate the benefit of this method by employing amine reactive monomers in the grafting-from step. This enables diverse postsynthetic functionalization for the facile screening of chemical motifs to enhance response capabilities to mustard blister agents. Surface-tethered triarylmethanol-containing polymers with four distinct functional groups are prepared and challenged with the vapor of 2-chloroethyl ethyl sulfide (CEES), a simulant of mustard agent, in humid air. Importantly, hydroxyl groups effectively improve CWA response and the resulting polymer brushes show chain collapse after both CEES and diethylchlorophosphate (DCP) treatment. Our results illustrate that the grafting-to and from method can be used to grow functional and robust polymer coatings for various applications.

36 MATERIALS SCIENCE↗

Reversible Binding Interfaces Made of Microstructured Polymer Brushes

The polymer brush architecture of the end-tethered polymer molecules is one of the most widely used efficient methods to regulate interfacial interactions in colloidal systems found in live matter and manufactured materials. Emerging applications of polymer brush structures require solutions to new tasks in the control of interfacial interactions. The rapid development of live cell manufacturing relies on scalable and efficient cell harvesting methods. Stimuli-responsive surfaces made of surface-grafted poly(N-isopropylacrylamide) (PNIPAM) can bind and detach the adherent cell upon changes in temperature and have been used for cell growth and harvesting. The applications are limited by the requirement to satisfy a range of PNIPAM coating characteristics that depend on the dimensions of the integrin complex in the cell membrane and the basal surface. The analysis of the microstructured surfaces, when adhesive and disjoining functions of the microdomains are decoupled, shows that many limitations of PNIPAM one-component coatings can be avoided by using a much broader range of structural characteristics of the microstructured interfaces composed of alternating disjoining PNIPAM domains and adhesive polymeric domains with cell-affinity functional groups. Temperature-controlled reversible adhesion to such microstructured interfaces is studied here experimentally with model systems of solid spherical particles and by employing simulations for solid and soft membranes interacting with the microstructured surfaces to mimic interactions with soft and solid disk-like particles.

36 MATERIALS SCIENCE↗

Tuning dispersity of linear polymers and polymeric brushes grown from nanoparticles by atom transfer radical polymerization

Molecular weight distribution imposes considerable influence on the properties of polymers, making it an important parameter, impacting morphology and structural behavior of polymeric materials. Atom transfer radical polymerization (ATRP) has established itself as a powerful tool to prepare polymers with predetermined molecular weight, preserved chain-end functionality, and low dispersity. More recently, ATRP has also been shown to provide a means to deliberately broaden molecular weight distributions, and, via retaining living chain-ends, to enable the formation of block copolymers with designed block dispersity, featuring new microstructures and potentially attractive properties. Here, similar methodologies have been developed to facilitate tuning of the dispersity of polymeric brushes grown from nanoparticles thus resulting in hybrid materials with enhanced fracture toughness and high inorganic content. Recent advances have given access to brush architectures comprised of uni- and bimodal block copolymers with unique morphologies along with interesting mechanical, thermal, and optical properties.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗