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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 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
NASA NTRS2007

Feasibility Study of Vapor-Mist Phase Reaction Lubrication Using a Thioether Liquid

A primary technology barrier preventing the operation of gas turbine engines and aircraft gearboxes at higher temperatures is the inability of currently used liquid lubricants to survive at the desired operating conditions over an extended time period. Current state-of-the-art organic liquid lubricants rapidly degrade at temperatures above 300 C; hence, another form of lubrication is necessary. Vapor or mist phase reaction lubrication is a unique, alternative technology for high temperature lubrication. The majority of past studies have employed a liquid phosphate ester that was vaporized or misted, and delivered to bearings or gears where the phosphate ester reacted with the metal surfaces generating a solid lubricious film. This method resulted in acceptable operating temperatures suggesting some good lubrication properties, but the continuous reaction between the phosphate ester and the iron surfaces led to wear rates unacceptable for gas turbine engine or aircraft gearbox applications. In this study, an alternative non-phosphate liquid was used to mist phase lubricate a spur gearbox rig operating at 10,000 rpm under highly loaded conditions. After 21 million shaft revolutions of operation the gears exhibited only minor wear.

Morales, Wilfredo↗
NASA NTRS2014

Observations of Spacecraft Bearing Lubricant Redistribution Based on Thermal Conductance Measurements

The performance and life of precision ball bearings are critically dependent on maintaining a quantity of oil at the ball/race interface that is sufficient to support a robust protective film. In space applications, where parched conditions are intentionally the norm, harsh operating conditions can displace the small reserves of oil, resulting in reduced film thickness and premature wear. In the past, these effects have proven difficult to model or to measure experimentally. This paper describes a study addressing this challenge, where bearing thermal conductance measurements are employed to infer changes in lubricant quantity at the critical rolling interfaces. In the first part of the paper, we explain how the lubricant's presence and its quantity impacts bearing thermal conductance measurements. For a stationary bearing, we show that conductance is directly related to the lubricant quantity in the ball/race contacts. Hence, aspects of bearing performance related to oil quantity can be understood and insights improved with thermal conductance data. For a moving bearing, a different mechanism of heat transfer dominates and is dependent on lubricant film thickness on the ball. In the second part of the report, we discuss lubricant quantity observations based on bearing thermal conductance measurements. Lubricant quantity, and thus bearing thermal conductance, depends on various initial and operating conditions and is impacted further by the run-in process. A significant effect of maximum run-in speed was also observed, with less oil remaining after obtaining higher speeds. Finally, we show that some of the lubricant that is displaced between the ball and race during run-in operation can be recovered during rest, and we measure the rate of recovery for one example.

Takeuchi, Yoshimi R.↗
DOE OSTI2012

Full Life Wind Turbine Gearbox Lubricating Fluids

Industrial gear box lubricants typically are hydrocarbon based mineral oils with considerable amounts of additives to overcome the lack of base fluid properties like wear protection, oxidation stability, load carrying capacity, low temperature solidification and drop of viscosity at higher temperatures. For today's wind turbine gearboxes, the requirements are more severe and synthetic hydrocarbon oils are used to improve on this, but all such hydrocarbon based lubricants require significant amounts of Extreme Pressure (EP) additives to meet performance requirements. Perfluoropolyether (PFPE) fluids provide load carrying capacity as an inherent property. During the course of the project with the main tasks of 'Establish a Benchmark', 'Lubricant Evaluation', 'Full Scale Gearbox Trial' and 'Economic Evaluation', the PAO Reference oil exhibited significant changes after laboratory gear testing, in service operation in the field and full scale gearbox trial. Four hydrocarbon base oils were selected for comparison in the benchmarking exercise and showed variation with respect to meeting the requirements for the laboratory micro-pitting tests, while the PFPE fluid exceeded the requirements even with the material taken after the full scale gear box trial. This is remarkable for a lubricant without EP additives. Laboratory bearing tests performed on the PFPE fluids before and after the full scale gear box trial showed the results met requirements for the industry standard. The PFPE fluid successfully completed the full scale gear box test program which included baseline and progressive staged load testing. The evaluation of gears showed no micro-pitting or objectionable wear. By the final stage, lubricant film thickness had been reduced to just 21% of its original value, this was by design and resulted in a lambda ratio of well below 1.

17 WIND ENERGY↗
DOE OSTI2018

Polyalkylene Glycol (PAG) Based Lubricant for Light & Medium Duty Axles

The axle lubricant (SAE 75W-140) widely used in the market place over the last few years is primarily formulated from polyalpha olefin (PAO) basestock. This investigation focused on polyalkylene glycol (PAG) base stock which is significantly different chemically from PAO and because of their polar nature it is hypothesized that it can adsorb relatively easily on contacting surfaces resulting in significant friction reduction and improve fuel economy. Axle efficiency is generally quite high at high torque range but it could be quite low at low torque range representative of EPA drive cycles. Therefore, this project primarily focus on improving axle efficiency in the low torque range while maintaining all durability attributes. The objective of this project is to develop novel lubricant formulations that are expected to improve the fuel efficiency of light, medium, heavy-duty, and military vehicles by at least 2% over Society of Automotive Engineers (SAE) 75W-140 axle lubricants (improvement based on comparative results from engine dynamometer testing, chassis dynamometer testing or test track, e.g., SAE J1321) without adverse impacts on vehicle performance or durability. The proposed research project followed a structured approach beginning with lubricant formulations by varying base oil chemistry and additive components followed by physical property characterization. Lubricant performance evaluations started with simple laboratory friction, wear, oxidation, and corrosion tests which guided into identification of performance areas requiring improvements. This required an iterative lubricant reformulation. Once a few acceptable formulations were identified, they are evaluated in more complex component tests including ASTM tests (L-37 - load carrying capacity under low speed and high torque, L42 – load carrying properties under high speed and shock loading, L-60 - thermal and oxidative stability, and L-33-1 moisture corrosion resistance). Two issues were observed following L-42 tests; toxicological and foaming. This required reformulation and repeating all ASTM tests. During repeat tests it was observed that some of the additives precipitated out of solution. Since it was discovered quite late in the program, and the time it may need to find a solution to this issue, the team changed direction of the program to switch to use of an oil soluble PAG as a co-basestock (15-30%) with mineral oil used in a commercial formulation (SAE 75W-85). This formulation strategy helped passing all ASTM tests. This was followed by Ford proprietary axle efficiency, gear wear, and chassis roll dynamometer tests for fuel economy evaluations. Axle efficiency was improved up to 7% when a full PAG formulation was used but no such significant improvement was observed with PAG as co-basestock formulation. Chassis roll fuel economy improved by 1.9% with PAG co-basestock formulation (conforming to SAE 75W-85) compared to SAE 75W-140 baseline. However, it was observed that the improvement is mostly due to reduced viscosity of candidate formulation when compared to a full mineral oil based SAE 75W-85 formulation. PAG as co-basestock also exhibited unacceptable wear in proprietary gear wear test. This investigation highlighted challenges with PAG formulations including identification of additive components that stay in PAG solution for intended duration, and meeting component durability requirement.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Self-Lubricating Bushing Testing for John Day Dam Ka plan Turbine Replacement

The goal of this testing program is to find suitable self-lubricated alternatives to replace the in use oil lubricated grooved-bronze bushing in Kaplan runner hubs that are currently being utilized at John Day Dam operated by the U.S. Army Corps of Engineers (USACE). Scaled bushing testing utilizing a Pacific Northwest National Laboratory designed, fabricated, and operated Bushing Test Stand under the direction and funding from USACE determined that self-lubricated bushings tested appear capable of outperforming the current oil-lubricated bronze bushings. Performance tests are focused on durability which includes cyclic load bearing properties and articulations under various loading scenarios. This testing was performed at nominally 1/5 th scale. A scaling sensitivity analysis determined that scaled testing results apply to prototypic size. This report shows the direct comparison between the current baseline bronze bushing to self-lubricated bushings from various manufacturers. Bushing data like coefficient of friction and bushing material loss (associated with bushing wear) was determined. Self-lubricated bushings tested include products manufactured specifically for hydropower applications by the following companies: Trelleborg, Kamatics, Anonymous, and Tenneco/Deva.

42 ENGINEERING↗
DOE OSTI2019

Branched Bio-Lubricant Base Oil Production through Aldol Condensation

Currently, lubricant base oils are derived from petroleum, a nonrenewable feedstock that contributes to greenhouse gas emissions. Bioderived, renewable lubricant base oils can mitigate environmental challenges and offer superior cold flow properties by incorporating branches to the base oil's hydrocarbon backbone with an appropriate synthetic strategy. A strategy was developed to synthesize branched alkanes for lubricant base oil in two steps from 12-tricosanone, obtained from bioderived fatty acids, and furfural, obtained from lignocellulosic biomass. The reaction pathway involves carbon–carbon coupling through aldol condensation followed by hydrodeoxygenation (HDO). Various solvents (non-polar, aprotic and polar, protic) and reaction conditions were screened to achieve a maximum yield of 94.3% of aldol condensation products, containing the majority of a C 33 furan (79.5%) followed by a C 28 furan (14.8%). Subsequent HDO of aldol condensation products over an Ir-ReO x /SiO 2 catalyst produced lubricant-ranged branched alkanes (C 28 and C 33 ) with 61.4% yield and small fractions (<11%) of alkanes with carbon numbers between C 15 and C 10 . The viscous properties of the produced bio-lubricant base oil were comparable to commercial petroleum-derived Group III and Group IV base oils. Overall, this approach serves as a potential stepping-stone to replace petroleumderived base oils and, in turn, reduce greenhouse gas emissions associated with current lubricant production.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2018

The Effect of Lubricant Composition on White Etching Crack Failures

White etching cracks (WECs) are the dominant mode of failure for wind turbine gearbox bearings. These failures are characterized by subsurface initiation and local region of microstructural alterations adjacent to the crack faces. The definitive cause of WECs within the field is unknown, because of this laboratory replication has proved difficult. At a benchtop scale, specific lubricant formulations referred to as bad reference oils (BROs) are often employed to aid in the formation of WECs; however, exactly how these lubricants induce WECs is unknown. The present work intends to elucidate how these lubricants facilitate the formation of WECs by systematically varying the additives which are found in BROs and studying the effect that these additive combinations have on time until failure, as well as tribofilm development. It was found that the lubricant containing Zinc dialkyldithiophosphate alone led to the formation of WECs sooner than any lubricant studied. It was also documented that a lubricants frictional characteristics play a more dominant role than the tribofilm characteristics.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Carbon-based tribofilms from lubricating oils

Moving mechanical interfaces are commonly lubricated and separated by a combination of fluid films and solid 'tribofilms', which together ensure easy slippage and long wear life(1). The efficacy of the fluid film is governed by the viscosity of the base oil in the lubricant; the efficacy of the solid tribofilm, which is produced as a result of sliding contact between moving parts, relies upon the effectiveness of the lubricant's anti-wear additive (typically zinc dialkyldithiophosphate)(2). Minimizing friction and wear continues to be a challenge, and recent efforts have focused on enhancing the anti-friction and anti-wear properties of lubricants by incorporating inorganic nanoparticles and ionic liquids(3,4). Here, we describe the in operando formation of carbon-based tribofilms via dissociative extraction from base-oil molecules on catalytically active, sliding nanometre-scale crystalline surfaces, enabling base oils to provide not only the fluid but also the solid tribofilm. We study nanocrystalline catalytic coatings composed of nitrides of either molybdenum or vanadium, containing either copper or nickel catalysts, respectively. Structurally, the resulting tribofilms are similar to diamond-like carbon(5). Ball-on-disk tests at contact pressures of 1.3 gigapascals reveal that these tribofilms nearly eliminate wear, and provide lower friction than tribofilms formed with zinc dialkyldithiophosphate. Reactive and ab initio molecular-dynamics simulations show that the catalytic action of the coatings facilitates dehydrogenation of linear olefins in the lubricating oil and random scission of their carbon-carbon backbones; the products recombine to nucleate and grow a compact, amorphous lubricating tribofilm.

Erdemir, Ali↗
DOE OSTI2022

Conversion of plastic waste into high-value lubricants: techno-economic analysis and life cycle assessment

Given the low recycling rate of plastic waste in the United States due to low economic incentives, it is of great interest to develop a technology to upgrade plastic waste with favorable economics. Plastic upcycling to valuable chemicals could ensure a circular economy for plastics and reduce the environmental burden caused by their end use cycle and disposal. A conceptual facility to convert 250 metric ton (MT) per day of plastic waste was modeled; the main product was a high-quality liquid (HQL) with a similar performance to polyalphaolefin (PAO) lubricants. The modeled process had a lubricant yield of up to 90% based on the experimental results at the laboratory scale. Techno-economic analysis (TEA) and life cycle assessment (LCA) were also performed to evaluate the process economics and its environmental impact. By using a mixture of colored and natural high-density polyethylene (HDPE), the production cost was in the range of 0.6–1.98 dollars per kg of lubricant, depending on the operating conditions. The life cycle emissions were in the range of 0.48–1.2 kg CO 2e kg Lub -1 showing, for the best case scenario, a 52% reduction relative to the emissions for petroleum lubricants, and a 74% reduction relative to the emissions for PAO lubricants. Finally, the impacts of the lubricant yield, the catalyst amount, and reaction time were evaluated, and their effect on the final production cost was discussed.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1972

Influence of liquid lubricant properties on their performance.

The influence of lubricant properties on performance is considered in connection with various mechanisms of lubrication. The effects of temperature and pressure on viscosity, which is important in hydrodynamic and elastohydrodynamic lubrication, is presented using a correlation postulated by Roelands. Under elastohydrodynamic conditions it is important to distinguish between the influence of lubricant properties within the inlet region and the Hertz region since each performs different functions. The role of lubricant transport properties such as surface tension is considered in connection with lubricant starvation.

Wedeven, V.↗
NASA NTRS1973

Rheology in lubrication

The rheological effects on lubrication are discussed. The types of lubrication considered are thick film hydrodynamic lubrication and thin film elastohydrodynamic lubrication. The temperature-viscosity, viscoelastic, shear-thinning, and normal stess effects on the lubrication of journal bearings are analyzed. A graph of the pressure distribution of viscoelastic liquids in journal bearings is provided. Mathematical models are developed to define the effects of various properties of the lubricants on friction reduction.

Cheng, H. S.↗
NASA NTRS1975

Operating limitations of high speed jet lubricated ball bearings

A parametric study was performed with 120-mm bore angular-contact ball bearings having a nominal contact angle of 20 degrees. The bearings had either an inner- or an outer-race land riding cage, and lubrication was by recirculating oil jets which had either a single or dual orifice. Thrust load, speed, and lubricant flow rate were varied. Test results were compared with those previously reported and obtained from bearings of the same design which were under-race lubricated but run under the same conditions. Jet lubricated ball bearings were limited to speeds less than 2,500,000 DN, and bearings having inner-race land riding cages produced lower temperatures than bearings with outer-race land riding cages. For a given lubricant flow rate dual orifice jets produced lower bearing temperatures than single orifice jets, but under-race lubrication produced lower bearing temperatures under all conditions of operation with no apparent bearing speed limitation.

Zaretsky, E. V.↗
NASA NTRS1975

Operating limitations of high-speed jet-lubricated ball bearings

A parametric study was performed with 120-mm bore angular-contact ball bearings having a nominal contact angle of 20 deg. The bearings either had an inner- or an outer-race land riding cage. Lubrication was by recirculating oil jets. The oil jets either had a single or dual orifice. Thrust load, speed, and lubricant flow rate were varied. Test results were compared with those previously reported and obtained from bearings of the same design which were under-race lubricated but run under the same conditions. Jet lubricated ball bearings were limited to speeds less than 2,500,000 DN. Bearings having inner-race land riding cages produced lower temperatures than bearings with outer-race land riding cages. For a given lubricant flow rate dual orifice jets produced lower bearing temperatures than single orifice jets. However, under-race lubrication produced under all conditions of operation lower bearing temperatures with no apparent bearing speed limitation.

Zaretsky, E. V.↗
NASA NTRS1978

Emergency and microfog lubrication and cooling of bearings for Army helicopters

An analysis and system study was performed to provide design information regarding lubricant and coolant flow rates and flow paths for effective utilization of the lubricant and coolant in a once-through oil-mist (microfog) and coolant air system. A system was designed, manufactured, coupled with an existing rig and evaluation tests were performed using 46 mm bore split-inner angular-contact ball bearings under 1779N (400 lb.) thrust load. An emergency lubrication aspirator system was also manufactured and tested under lost lubricant conditions. The testing demonstrated the feasibility of using a mist oil and cooling air system to lubricate and cool a high speed helicopter engine mainshaft bearing. The testing also demonstrated the feasibility of using an emergency aspirator lubrication system as a viable survivability concept for helicopter mainshaft engine bearing for periods as long as 30 minutes.

Rosenlieb, J. W.↗
NASA NTRS1979

Determination of lubricant selection based on elastohydrodynamic film thickness and traction measurement

The project was conducted to aid in the development of an elastohydrodynamic specification for military lubricants. Experiments were conducted with a rolling disk apparatus designed to simulate a bearing or gear type contact. Measurements included lubricant film thickness, lubricant breakdown and traction for a range of loads, speeds, temperatures, and surface roughnesses. Several lubricants were used in the investigations including a traction fluid, two synthetic paraffinic lubricants and several lubricants conforming to MIL-L 7808 and 23699 specifications. Recommendations regarding an EHD specification are included.

Dow, T. A.↗
NASA NTRS1979

Wide-temperature-spectrum self-lubricating coatings prepared by plasma spraying

Self-lubricating, multicomponent coatings, which lubricate over a wide range of operating conditions, are described. The coatings were successfully applied by plasma-spraying mixed powders onto superalloy substrates. They were evaluated in friction and wear experiments, and in sliding contact bearing tests. These coatings are wear resistant by virtue of their self lubricating characteristics rather than because of extreme hardness; a further benefit is low friction. Experiments with simple pin on disk sliding specimens and oscillating plain cylindrical bearing tests were performed to evaluate the tribological properties of the coatings. It was shown that coatings of nichrome, glass and calcium fluoride are self-lubricating from about 500 to 900 C, but give high friction at the lower temperatures. The addition of silver to the coating composition improved the low temperature bearing properties and resulted in coatings which are self-lubricating from cryogenic temperatures to at least 870 C; they are therefore, wide temperature spectrum, self-lubricating compositions.

Sliney, H. E.↗
NASA NTRS1979

Wide-temperature-spectrum self-lubricating coatings prepared by plasma spraying

Self-lubricating, multicomponent coatings, which lubricate over a wide range of operating conditions, are described. The coatings have been successfully applied by plasma-spraying mixed powders onto superalloy substrates. They have been evaluated in friction and wear experiments, and in sliding contact bearing tests. These coatings are wear resistant by virtue of their self-lubricating characteristics rather than because of extreme hardness; a further benefit is low friction. Experiments with simple pin on disk sliding specimens and oscillating plain cylindrical bearing tests were performed to evaluate the tribological properties of the coatings. It was shown that coatings of nichrome, glass and calcium fluoride are self-lubricating from about 500 to 900 C, but give high friction at the lower temperatures. The addition of silver to the coating composition improved the low temperature bearing properties and resulted in coatings which are self-lubricating from cryogenic temperatures to at least 870 C; they are therefore 'wide temperature spectrum,' self-lubricating compositions.

Sliney, H. E.↗
NASA NTRS1981

Performance of jet- and inner-ring-lubricated 35 millimeter bore ball bearings operating to 2.5 million DN

Parametric tests were conducted with a 35 millimeter bore, angular contact ball bearing having a single outer land guided cage. Lubrication was achieved by flowing oil through axial grooves and radial holes machined in the inner ring of the bearing. Test conditions were a thrust load of 667 N (150 lb), shaft speeds from 48,000 to 72,000 rpm, and an oil inlet temperature of 394 K (250 F). Data from tests where the distribution of the total oil supplied to the inner ring was 50 percent for bearing lubrication and 50 percent for bearing inner ring cooling were compared with those where the distribution pattern was 25 percent lubrication and 75 percent cooling. Successful operation was experienced with both the 50-50 and 25-75 percent flow distribution patterns to 2.5 million DN. The 50-50 percent flow pattern provided the cooler bearing operation of the two inner ring lubricated bearings. The jet lubricated bearing had lower outer ring and higher inner ring temperatures than the inner ring lubricated bearings. Maximum power loss of 2.8 kW (3.7 hp) was experienced with the 25-75 percent flow distribution, and maximum percent cage slip of 7.0 occurred at 72,300 rpm with the 50-50 percent flow distribution.

Schuller, F., T.↗