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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 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
NASA NTRS1987

Hot piston ring tests

As part of the DOE/NASA Automotive Stirling Engine Project, tests were made at NASA Lewis Research Center to determine whether appendix gap losses could be reduced and Stirling engine performance increased by installing an additional piston ring near the top of each piston dome. An MTI-designed upgraded Mod I Automotive Stirling Engine was used. Unlike the conventional rings at the bottom of the piston, these hot rings operated in a high temperature environment (700 C). They were made of a high temperature alloy (Stellite 6B) and a high temperature solid lubricant coating (NASA Lewis-developed PS-200) was applied to the cylinder walls. Engine tests were run at 5, 10, and 15 MPa operating pressure over a range of operating speeds. Tests were run both with hot rings and without to provide a baseline for comparison. Minimum data to assess the potential of both the hot rings and high temperature low friction coating was obtained. Results indicated a slight increase in power and efficiency, an increase over and above the friction loss introduced by the hot rings. Seal leakage measurements showed a significant reduction. Wear on both rings and coating was low.

Allen, David J.↗
NASA NTRS2004

Future Issues and Approaches to Health Monitoring and Failure Prevention for Oil-Free Gas Turbines

Recent technology advances in foil air bearings, high temperature solid lubricants and computer based modeling has enabled the development of small Oil-Free gas turbines. These turbomachines are currently commercialized as small (<100 kW) microturbine generators and larger machines are being developed. Based upon these successes and the high potential payoffs offered by Oil-Free systems, NASA, industry, and other government entities are anticipating Oil-Free gas turbine propulsion systems to proliferate future markets. Since an Oil-Free engine has no oil system, traditional approaches to health monitoring and diagnostics, such as chip detection, oil analysis, and possibly vibration signature analyses (e.g., ball pass frequency) will be unavailable. As such, new approaches will need to be considered. These could include shaft orbit analyses, foil bearing temperature measurements, embedded wear sensors and start-up/coast down speed analysis. In addition, novel, as yet undeveloped techniques may emerge based upon concurrent developments in MEMS technology. This paper introduces Oil-Free technology, reviews the current state of the art and potential for future turbomachinery applications and discusses possible approaches to health monitoring, diagnostics and failure prevention.

DellaCorte, Christopher↗
NASA NTRS2003

NASA PS304 Lubricant Tested in World's First Commercial Oil-Free Gas Turbine

In a marriage of research and commercial technology, a 30-kW Oil-Free Capstone microturbine electrical generator unit has been installed and is serving as a test bed for long-term life-cycle testing of NASA-developed PS304 shaft coatings. The coatings are used to reduce friction and wear of the turbine engine s foil air bearings during startup and shut down when sliding occurs, prior to the formation of a lubricating air film. This testing supports NASA Glenn Research Center s effort to develop Oil-Free gas turbine aircraft propulsion systems, which will employ advanced foil air bearings and NASA s PS304 high temperature solid lubricant to replace the ball bearings and lubricating oil found in conventional engines. Glenn s Oil-Free Turbomachinery team s current project is the demonstration of an Oil-Free business jet engine. In anticipation of future flight certification of Oil-Free aircraft engines, long-term endurance and durability tests are being conducted in a relevant gas turbine environment using the Capstone microturbine engine. By operating the engine now, valuable performance data for PS304 shaft coatings and for industry s foil air bearings are being accumulated.

Weaver, Harold F.↗
NASA NTRS2001

The Effect of Journal Roughness and Foil Coatings on the Performance of Heavily Loaded Foil Air Bearings

Foil air bearing load capacity tests were conducted to investigate if a solid lubricant coating applied to the surface of the bearing's top foil can function as a break-in coating. Two foil coating materials, a conventional soft polymer film (polyimide) and a hard ceramic (alumina), were independently evaluated against as-ground and worn (run-in) journals coated with NASA PS304, a high-temperature solid lubricant composite coating. The foil coatings were evaluated at journal rotational speeds of 30,000 rpm and at 25 C. Tests were also performed on a foil bearing with a bare (uncoated) nickel-based superalloy top foil to establish a baseline for comparison. The test results indicate that the presence of a top foil solid lubricant coating is effective at increasing the load capacity performance of the foil bearing. Compared to the uncoated baseline, the addition of the soft polymer coating on the top foil increased the bearing load coefficient by 120% when operating against an as-ground journal surface and 85 percent against a run-in journal surface. The alumina coating increased the load coefficient by 40% against the as-ground journal but did not have any affect when the bearing was operated with the run-in journal. The results suggest that the addition of solid lubricant films provide added lubrication when the air film is marginal indicating that as the load capacity is approached foil air bearings transition from hydrodynamic to mixed and boundary lubrication.

Radil, Kevin C.↗
NASA NTRS1997

The Role of Tribology in the Development of an Oil-Free Turbocharger

Gas-turbine-based aeropropulsion engines are technologically mature. Thus, as with any mature technology, revolutionary approaches will be needed to achieve the significant performance gains that will keep the U.S. propulsion manufacturers well ahead of foreign competition. One such approach is the development of oil-free turbomachinery utilizing advanced foil air bearings, seals, and solid lubricants. By eliminating oil-lubricated bearings and seals and supporting an engine rotor on an air film, significant improvements can be realized. For example, the entire oil system including pipes, lines, filters, cooler, and tanks could be removed, thereby saving considerable weight. Since air has no thermal decomposition temperature, engine systems could operate without excessive cooling. Also, since air bearings have no diameter-rpm fatigue limits (D-N limits), engines could be designed to operate at much higher speeds and higher density, which would result in a smaller aeropropulsion package. Because of recent advances in compliant foil air bearings and high temperature solid lubricants, these technologies can be applied to oil-free turbomachinery. In an effort to develop these technologies and to demonstrate a project along the path to an oil-free gas turbine engine, NASA has undertaken the development of an oil-free turbocharger for a heavy duty diesel engine. This turbomachine can reach 120000 rpm at a bearing temperature of 540 C (1000 F) and, in comparison to oil-lubricated bearings, can increase efficiency by 10 to 15 percent because of reduced friction. In addition, because there are no oil lubricants, there are no seal-leakage-induced emissions.

Dellacorte, Christopher↗
DOE OSTI2021

Bioinspired nonwetting surfaces for corrosion inhibition over a range of temperature and corrosivity

Applications of superhydrophobic (SHS) and lubricant infused surfaces (LIS) involve exposure to corrosive environments from the acidic to the basic, at a range of temperatures, that are not fully characterized. Here, we present for the first time a multifactorial study of the effects of surface fabrication method, surface modification, surface functionalization time, temperature and pH of the immersion medium on the corrosion performance of nonwetting copper surfaces. Bioinspired SHS and LIS fabricated using facile methods of etching and electrodeposition are systematically assessed using potentiodynamic polarization measurements for their corrosion resistance in saline solution (pH ≈7) over a temperature range 23–85°C. SHS and LIS are shown to exhibit diminished corrosion rate, by up to two orders of magnitude, compared to bare copper surface. An Arrhenius model is developed for the first time, describing the temperature- dependent corrosion rate of SHS and LIS. Electrochemical impedance spectroscopy is used to show that corrosion resistance of LIS is larger by three orders of magnitude in extremely acidic (pH = 1) and by an order magnitude in extremely alkaline (pH = 14) media compared to bare copper surface. Etched LIS are generally more resistant to corrosion compared to SHS at all temperatures with excellent microstructural durability.

42 ENGINEERING↗
NASA NTRS1986

Solid lubrication design methodology, phase 2

The high temperature performance of solid lubricated rolling elements was conducted with a specially designed traction (friction) test apparatus. Graphite lubricants containing three additives (silver, phosphate glass, and zinc orthophosphate) were evaluated from room temperature to 540 C. Two hard coats were also evaluated. The evaluation of these lubricants, using a burnishing method of application, shows a reasonable transfer of lubricant and wear protection for short duration testing except in the 200 C temperature range. The graphite lubricants containing silver and zinc orthophosphate additives were more effective than the phosphate glass material over the test conditions examined. Traction coefficients ranged from a low of 0.07 to a high of 0.6. By curve fitting the traction data, empirical equations for slope and maximum traction coefficient as a function of contact pressure (P), rolling speed (U), and temperature (T) can be developed for each lubricant. A solid lubricant traction model was incorporated into an advanced bearing analysis code (SHABERTH). For comparison purposes, preliminary heat generation calculations were made for both oil and solid lubricated bearing operation. A preliminary analysis indicated a significantly higher heat generation for a solid lubricated ball bearing in a deep groove configuration. An analysis of a cylindrical roller bearing configuration showed a potential for a low friction solid lubricated bearing.

Pallini, R. A.↗
NASA NTRS1990

Silicon Nitride Balls For Cryogenic Bearings

Resistance to wear greater than that of 440C steel. Experiments show lives of ball bearings immersed in liquid nitrogen or liquid oxygen increased significantly when 440C steel balls (running on 440C steel races) replaced by balls of silicon nitride. Developed for use at high temperatures, where lubrication poor or nonexistent. Best wear life of any bearing tested to date and ball material spalls without fracturing. Plans for future tests call for use of liquid oxygen as working fluid.

Butner, Myles F.↗
NASA NTRS1992

Studies of the kinetics and mechanisms of perfluoroether reactions on iron and oxidized iron surfaces

Polymeric perfluoroalkylethers are being considered for use as lubricants in high temperature applications, but have been observed to catalytically decompose in the presence of metals. X-ray photoelectron spectroscopy (XPS) and temperature programmed desorption (TPD) were used to explore the decomposition of three model fluorinated ethers on clean polycrystalline iron surfaces and iron surfaces chemically modified with oxygen. Low temperature adsorption of the model fluorinated ethers on the clean, oxygen modified and oxidized iron surfaces was molecular. Thermally activated defluorination of the three model compounds was observed on the clean iron surface at remarkably low temperatures, 155 K and below, with formation of iron fluoride. Preferential C-F bond scission occurred at the terminal fluoromethoxy, CF3O, of perfluoro-1-methoxy-2-ethoxy ethane and perfluoro-1-methoxy-2-ethoxy propane and at CF3/CF2O of perfluoro-1,3-diethoxy propane. The reactivity of the clean iron toward perfluoroalkylether decomposition when compared to other metals is due to the strength of the iron fluoride bond and the strong electron donating ability of the metallic iron. Chemisorption of an oxygen overlayer lowered the reactivity of the iron surface to the adsorption and decomposition of the three model fluorinated ethers by blocking active sites on the metal surface. Incomplete coverage of the iron surface with chemisorbed oxygen results in a reaction which resembles the defluorination reaction observed on the clean iron surface. Perfluoro-1-methoxy-2-ethoxy ethane reacts on the oxidized iron surface at 138 K, through a Lewis acid assisted cleavage of the carbon oxygen bond, with preferential attack at the terminal fluoromethoxy, CF3O. The oxidized iron surface did not passivate, but became more reactive with time. Perfluoro-1-methoxy-2-ethoxy propane and perfluoro-1,3-diethoxy propane desorbed prior to the observation of decomposition on the oxidized iron surface.

Napier, Mary E.↗
NASA NTRS2008

Atomized BaF2-CaF7 for Better-Flowing Plasma-Spray Feedstock

Atomization of a molten mixture of BaF2 and CaF2 has been found to be superior to crushing of bulk solid BaF2- CaF2 as a means of producing eutectic BaF2-CaF2 powder for use as an ingredient of the powder feedstock of a high-temperature solid lubricant material known as PS304. Developed to reduce friction and wear in turbomachines that incorporate foil air bearings, PS304 is applied to metal substrates by plasma spraying. The constituents of PS304 are: a) An alloy of 80 weight percent Ni and 20 weight percent Cr, b) Cr2O3, c) Ag, and d) The BaF2-CaF2 eutectic, specifically, 62 weight percent BaF2 and 38 weight percent CaF2. The superiority of atomization as a means of producing the eutectic BaF2-CaF2 powder lies in (1) the shapes of the BaF2-CaF2 particles produced and (2) the resulting flow properties of the PS304 feedstock powder: The particles produced through crushing are angular, whereas those produced through atomization are more rounded. PS304 feedstock powder containing the more rounded BaF2-CaF2 particles flows more freely and more predictably, as is preferable for plasma spraying.

DellaCorte, Christopher↗
NASA NTRS1995

Au/Cr Sputter Coating for the Protection of Alumina During Sliding at High Temperatures

A sputter deposited bilayer coating of gold and chromium was investigated as a potential solid lubricant to protect alumina substrates in applications involving sliding at high temperature. The proposed lubricant was tested in a pin-on-disk tribometer with coated alumina disks sliding against uncoated alumina pins. Three test parameters; temperature, load, and sliding velocity were varied over a wide range in order to determine the performance envelope on the gold/chromium (Au/Cr) solid lubricant film. The tribo-tests were run in an air atmosphere at temperatures of 25 to 1000 C, under loads of 4.9 to 49.0 N and at sliding velocities from 1 to 15 m/sec. Post test analyses included surface profilometry, wear factor determination and scanning electron microscopy/energy dispersive spectroscopy (SEM/EDS) examination of worn surfaces. Compared to unlubricated Al2O3 sliding, the use of the Au/Cr film reduced friction by 30 to 50 percent and wear by one to two orders of magnitude. Increases in test temperature resulted in lower friction and the Au/Cr film continued to provide low friction, about 0.3, even at 1000 C. Pin wear factors and friction were largely unaffected by increasing loads up to 29.4 N. Sliding velocity had essentially no effect on friction, however, increased velocity reduced coating life (total sliding distance). Based upon these research results, the Au/Cr film is a promising lubricant for moderately loaded, low speed applications operating at temperatures as high as 1000 C.

Benoy, Patricia A.↗
NASA NTRS1994

Evaluation of PS 212 Coatings Under Boundary Lubrication Conditions with an Ester-based Oil to 300 C

High friction and wear of turbine engine components occur during high temperature excursions above the oxidation threshold of the liquid lubricant. This paper reports on research to study the use of a high temperature self lubricating coating, PS 212 for back-up lubrication in the event of failure of the liquid lubricant. Pin on disk tests were performed under dry and boundary-lubricated conditions at disk temperatures up to 300 C. The liquid lubricant was a formulated polyol ester qualified under MIL L-23699. At test temperatures above the oil's thermal degradation level, the use of PS 212 reduced wear, providing a back-up lubricant effect.

Sliney, Harold E.↗
NASA NTRS1996

Pyrolytic Carbon As A Lubricant In Hot Ceramic Bearings

Pyrolytic carbon proves useful as solid lubricant in ceramic bearings in advanced gas-turbine engines, where high temperatures destroy liquid lubricants. Ethylene gas made to flow past bearings and pyrolized to replenish carbon lubricant particles.

Lauer, J. L.↗
NASA NTRS1993

Properties of Extruded PS-212 Type Self-Lubricating Materials

Research has been underway at the NASA Lewis Research Center since the 1960's to develop high temperature, self-lubricating materials. The bulk of the research has been done in-house by a team of researchers from the Materials Division. A series of self-lubricating solid material systems has been developed over the years. One of the most promising is the composite material system referred to as PS-212 or PM-212. This material is a powder metallurgy product composed of metal bonded chromium carbide and two solid lubricating materials known to be self-lubricating over a wide temperature range. NASA feels this material has a wide potential in industrial applications. Simplified processing of this material would enhance its commercial potential. Processing changes have the potential to reduce processing costs, but tribological and physical properties must not be adversely affected. Extrusion processing has been employed in this investigation as a consolidation process for PM-212/PS-212. It has been successful in that high density bars of EX-212 (extruded PM-212) can readily be fabricated. Friction and strength data indicate these properties have been maintained or improved over the P.M. version. A range of extrusion temperatures have been investigated and tensile, friction, wear, and microstructural data have been obtained. Results indicate extrusion temperatures are not critical from a densification standpoint, but other properties are temperature dependent.

Waters, W. J.↗