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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 163 records · Page 9
All sourcesNASA NTRSDOE OSTI
NASA NTRS1972

Comparative lubrication studies of OH-58A tail rotor drive shaft bearings

Comparative lubrication tests were run with OH-58A helicopter tail rotor drive shaft bearings. The tests were run in an outdoor environment with ambient temperatures ranging from 10 to 75 F. Dust was periodically applied to the bearings to simulate field conditions. The cause of bearing failure was associated with dust penetration. Rotor shaft failure was found to be caused by the shaft rotating in the standard rubber collar due to seizure of the bearings. Bearings with a positive rubbing seal having a MIL-G-81322 grease produced lives greater than with bearings having labyrinth seals and a mineral oil paste lubricant. An elongated collar prevented failure of the rotor shaft during bearing seizure. In a limited test, installation of tail boom shrouds over the bearings which excluded dust and water resulted in bearing lives in excess of 1800 hours or 1200 hours greater than the current 600 hours TBO, regardless of the lubricant-bearing combination used.

Dietrich, M. W.↗
NASA NTRS1976

Design and evaluation of a 3 million DN series-hybrid thrust bearing

The design and experimental evaluation of a series-hybrid thrust bearing, consisting of a 150-mm ball bearing and a centrifugally actuated, conical, fluid-film bearing, is presented. Tests were conducted up to 16,000 rpm and at this speed an axial load of 15,600 N (3500 lb) was safely supported by the hybrid bearing system. Through the series-hybrid bearing principle, the effective ball bearing speed was reduced to approximately one-half of the shaft speed. A speed reduction of this magnitude would result in a tenfold increase in the ball bearing fatigue life. A successful evaluation of fluid-film bearing lubricant supply failure was performed repeatedly at an operating speed of 10,000 rpm. A complete and smooth changeover to full-scale ball bearing operation was effected when the oil supply to the fluid-film bearing was cut off. Reactivation of the fluid-film oil supply system produced a flawless return to the original mode of hybrid operation.

Scibbe, H. W.↗
NASA NTRS1981

Introduction to ball bearings

The purpose of a ball bearing is to provide a relative positioning and rotational freedom while transmitting a load between two structures, usually a shaft and a housing. For high rotational speeds (e.g., in gyroscope ball bearings) the purpose can be expanded to include rotational freedom with practically no wear in the bearing. This condition can be achieved by separating the bearing parts with a coherent film of fluid known as an elastohydrodynamic film. This film can be maintained not only when the bearing carries the load on a shaft, but also when the bearing is preloaded to position the shaft to within micro- or nano-inch accuracy and stability. Background information on ball bearings is provided, different types of ball bearings and their geometry and kinematics are defined, bearing materials, manufacturing processes, and separators are discussed. It is assumed, for the purposes of analysis, that the bearing carries no load.

Hamrock, B. J.↗
NASA NTRS1989

Analysis of the SSME HPOTP bearing inlet cavity

Analysis of the flow in the Space Shuttle Main Engine (SSME) high pressure oxygen turbopump (HPOTP) bearing no. 1 inlet cavity was completed in support of return-to-flight. With the incorporation of several design changes in the Phase 2 turbopump, rotordynamic stability of the pumps was enhanced, but the durability and life of the LOX-cooled bearings has decreased. During the post-Challenger SSME recertification, the causes of limited bearing durability were investigated. One topic addressed was the flow environment upstream of the pump-end bearing and the effect of seal exit swirl and a cavity anti-vortex rib on the bearing environment and life. The objective is to define the hydrodynamic environment upstream of the pump-end bearing and determine the effect of seal exit swirl and the anti-vortex rib on bearing inlet swirl. The problem was posed as an axisymmetric cavity flow with the computational domain extending from the seal exit to the bearing inlet. This domain was discretized with 22800 grid points. Boundary conditions were obtained from a 1-D model of the SSME coolant path. The inlet Mach number was 0.19 and the problem was solved with the CMINT code utilizing the Briley-McDonald/Beam-Warming algorithm with preconditioning to speed convergence at low Mach numbers. Three parametric cases with inlet swirl of 50 percent shaft speed (labyrinth seal), 20 percent shaft speed (damping seal), and no inlet swirl were considered. Computational results indicate large vortical flow structures in the cavity, with the labyrinth, damping, and no-swirl cases yielding bearing inlet swirl rates of 14, 10, and 9 percent of shaft speed, respectively. When these results were used as input to the SHABRETH bearing model, limited durability could not be explained by these small differences in swirl. Also, based on these results, a proposed design change for the cavity anti-vortex rib was not implemented by the SSME chief engineer.

Mcconnaughey, P. K.↗
NASA NTRS1992

Cryogenic Magnetic Bearing Test Facility (CMBTF)

The Cryogenic Magnetic Bearing Test Facility (CMBTF) was designed and built to evaluate compact, lightweight magnetic bearings for use in the SSME's (space shuttle main engine) liquid oxygen and liquid hydrogen turbopumps. State of the art and tradeoff studies were conducted which indicated that a hybrid permanent magnet bias homopolar magnetic bearing design would be smaller, lighter, and much more efficient than conventional industrial bearings. A test bearing of this type was designed for the test rig for use at both room temperature and cryogenic temperature (-320 F). The bearing was fabricated from state-of-the-art materials and incorporated into the CMBTF. Testing at room temperature was accomplished at Avcon's facility. These preliminary tests indicated that this magnetic bearing is a feasible alternative to older bearing technologies. Analyses showed that the hybrid magnetic bearing is one-third the weight, considerably smaller, and uses less power than previous generations of magnetic bearings.

Source record↗
NASA NTRS1993

Lubrication of an 85-mm ball bearing with RP-1

A parametric experimental investigation of an 85 millimeter bore angular contact ball bearing running in RP-1 fuel was performed at speeds of 10000 to 24000 RPM. Thrust loads were varied from 4450 to 17800 Newtons (1000 to 4000 lbs.). Radial loads were varied from 1335 to 13350 Newtons (300 to 3000 lbs.). RP-1 lubrication for the bearing was provided through a stationary jet ring located adjacent to the test bearing outer ring. Increases in both the thrust and radial loads resulted in increased bearing temperature, while increases in shaft speed resulted in much more dramatic increases in bearing temperature. These trends are typical for ball bearings operating under these types of conditions. Results are given for outer ring temperatures of the test bearing at the various test conditions employed. In addition, the heat energy removed from the bearing by the RP-1 was determined by measuring the increase in temperature as the RP-1 passed through the bearing. Results showed that the amount of heat energy removed by the RP-1 increased with both shaft speed and RP-1 flow rate to the bearing.

Addy, Harold E., Jr.↗
NASA NTRS1993

Lubrication of an 85-mm ball bearing with RP-1

A parametric experimental investigation of an 85 millimeter bore angular contact ball bearing running in RP-1 fuel was performed at speeds of 10,000 to 24,000 rpm. Thrust loads were varied from 4450 to 17,800 Newtons (1000 to 4000 lbs.). Radial loads were varied from 1335 to 13,350 Newtons (300 to 3000 lbs.). RP-1 lubrication for the bearing was provided through a stationary jet ring located adjacent to the test bearing outer ring. Increases in both the thrust and radial loads resulted in increased bearing temperature, while increases in shaft speed resulted in much more dramatic increases in bearing temperature. These trends are typical for ball bearings operating under these types of conditions. Results are given for outer ring temperatures of the test bearing at the various test conditions employed. In addition, the heat energy removed from the bearing by the RP-1 was determined by measuring the increase in temperature as the RP-1 passed through the bearing. Results showed that the amount of heat energy removed by the RP-1 increased with both shaft speed and RP-1 flow rate to the bearing.

Addy, Harold E., Jr.↗
NASA NTRS1992

Component test results from the bearing life improvement program for the Space Shuttle Main Engine oxidizer turbopumps

Interim results from a component test program to improve ball bearing life in the Space Shuttle Main Engine oxygen turbopumps are presented. Two specific bearing applications, using liquid oxygen as the bearing coolant, are addressed. The first, the thrust bearing of the low pressure pump, operates at relatively slow speed with predominantly axial load and little temperature rise in the bulk coolant. Testing has demonstrated a very significant reduction in bearing wear by increasing the bearing internal clearance. Heat generation data was obtained that indicates heavy, intermittent cage-to-ball contact occurs, providing a possible explanation for the observed wear. The second application is the turbine end bearings of the high pressure pump. These bearings operate at high speed and load with the possibility of significant coolant vaporization. Tests on production bearings and bearings having modified internal clearance and curvature yielded scattered but generally poor lives. A dramatic improvement was achieved by coating the standard cage with a thin film of fluorinated ethylene propylene and 15 percent molybdenum disulfide. Very promising results have also been obtained by replacing the standard balls with ones made of silicon nitride, especially in combination with the coated cage.

Keba, John E.↗
NASA NTRS1994

Aerospace applications of magnetic bearings

Magnetic bearings have traditionally been considered for use in aerospace applications only where performance advantages have been the primary, if not only, consideration. Conventional wisdom has been that magnetic bearings have certain performance advantages which must be traded off against increased weight, volume, electric power consumption, and system complexity. These perceptions have hampered the use of magnetic bearings in many aerospace applications because weight, volume, and power are almost always primary considerations. This paper will review progress on several active aerospace magnetic bearings programs at SatCon Technology Corporation. The magnetic bearing programs at SatCon cover a broad spectrum of applications including: a magnetically-suspended spacecraft integrated power and attitude control system (IPACS), a magnetically-suspended momentum wheel, magnetic bearings for the gas generator rotor of a turboshaft engine, a vibration-attenuating magnetic bearing system for an airborne telescope, and magnetic bearings for the compressor of a space-rated heat pump system. The emphasis of these programs is to develop magnetic bearing technologies to the point where magnetic bearings can be truly useful, reliable, and well tested components for the aerospace community.

Downer, James↗
NASA NTRS1993

Finite-Difference Solutions of the Alternate Turbopump Development High-Pressure Oxidizer Turbopump Pump-End Ball-Bearing Cavity Flows

These analyses were undertaken to aid in the understanding of flow phenomena in the Alternate Turbopump Development (ATD) High-pressure Oxidizer Turbopump (HPOTP) Pump-end ball bearing (PEBB) cavities and their roles in turbopump vibration initiation and bearing distress. This effort was being performed to provide timely support to the program in a decision as to whether or not the program should be continued. In the first case, it was determined that a change in bearing through flow had no significant effect on axial preload. This was a follow-on to a previous study which had resulted in a redesign of the bearing exit cavity which virtually eliminated bearing axial loading. In the second case, a three-dimensional analysis of the inner-race-guided cage configuration was performed so as to determine the pressure distribution on the outer race when the shaft is 0.0002 inches off-center. The results indicate that there is virtually no circumferential pressure difference caused by the offset to contribute to bearing tilt. In the third case, axisymmetric analyses were performed on an outer-race guided cage configuration to determine the magnitude of tangential flow entering the bearing. The removed-shoulder case was analyzed as was the static diverter case. A third analysis where the preload spring was shielded by a sheet of metal for the baseline case was also performed. It was determined that the swirl entering the bearing was acceptable and the project decided to use the outer-race-guided cage configuration. In the fourth case, more bearing configurations were analyzed. These analyses included thermal modeling so as to determine the added benefit of injecting colder fluid directly onto the bearing inner-race contact area. The results of these analyses contributed to a programmatic decision to include coolant injection in the design.

Benjamin, Theodore G.↗
NASA NTRS2000

Load Capacity Estimation of Foil Air Journal Bearings for Oil-Free Turbomachinery Applications

This paper introduces a simple "Rule of Thumb" (ROT) method to estimate the load capacity of foil air journal bearings, which are self-acting compliant-surface hydrodynamic bearings being considered for Oil-Free turbo-machinery applications such as gas turbine engines. The ROT is based on first principles and data available in the literature and it relates bearing load capacity to the bearing size and speed through an empirically based load capacity coefficient, D. It is shown that load capacity is a linear function of bearing surface velocity and bearing projected area. Furthermore, it was found that the load capacity coefficient, D, is related to the design features of the bearing compliant members and operating conditions (speed and ambient temperature). Early bearing designs with basic or "first generation" compliant support elements have relatively low load capacity. More advanced bearings, in which the compliance of the support structure is tailored, have load capacities up to five times those of simpler designs. The ROT enables simplified load capacity estimation for foil air journal bearings and can guide development of new Oil-Free turbomachinery systems.

DellaCorte, Christopher↗
NASA NTRS2001

Comparison Between Oil-mist and Oil-jet Lubrication of High-speed, Small-bore, Angular-contact Ball Bearings

Parametric tests were conducted with an optimized 35-mm-bore-angular-contact ball bearing on a high-speed, high-temperature bearing tester. Results from both air-oil mist lubrication and oil-jet lubrication systems used to lubricate the bearing were compared to speeds of 2.5 x 10(exp 6) DN. The maximum obtainable speed with air-oil mist lubrication is 2.5 x 10(exp 6) DN. Lower bearing temperatures and higher power losses are obtained with oil-jet lubrication than with air-oil mist lubrication. Bearing power loss is a direct function of oil flow to the bearing and independent of oil delivery system. For a given oil-flow rate, bearing temperature and power loss increase with increases in speed. Bearing life is an inverse function of temperature, the difference in temperature between the individual bearing ring components, and the resultant elastohydrodynamic (EHD) film thicknesses. Bearing life is independent of the oil delivery system except as it affects temperature. Cage slip increased with increases in speed. Cage slip as high as 7 percent was measured and was generally higher with air-oil mist lubrication than with oil-jet lubrication.

Pinel, Stanley I.↗
NASA NTRS2001

Comparison Between Oil-Mist and Oil-Jet Lubrication of High-Speed, Small-Bore, Angular-Contact Ball Bearings

Parametric tests were conducted with an optimized 35-mm-bore-angular-contact ball bearing on a high-speed, high-temperature bearing tester. Results from both air-oil mist lubrication and oil-jet lubrication systems used to lubricate the bearing were compared to speeds of 2.5x10(exp 6) DN. The maximum obtainable speed with air-oil mist lubrication is 2.5x10(exp 6) DN. Lower bearing temperatures and higher power losses are obtained with oil-jet lubrication than with air-oil mist lubrication. Bearing power loss is a direct function of oil flow to the bearing and independent of oil delivery system. For a given oil-flow rate, bearing temperature and power loss increase with increases in speed. Bearing life is an inverse function of temperature, the difference in temperature between the individual bearing ring components, and the resultant elastohydrodynamic (EHD) film thicknesses. Bearing life is independent of the oil delivery system except as it affects temperature. Cage slip increased with increases in speed. Cage slip as high as 7% was measured and was generally higher with air-oil mist lubrication than with oil-jet lubrication.

Pinel, Stanley I.↗
NASA NTRS2002

The Role of Radial Clearance on the Performance of Foil Air Bearings

Load capacity tests were conducted to determine how radial clearance variations affect the load capacity coefficient of foil air bearings. Two Generation III foil air bearings with the same design but possessing different initial radial clearances were tested at room temperature against an as-ground PS304 coated journal operating at 30,000 rpm. Increases in radial clearance were accomplished by reducing the journal's outside diameter via an in-place grinding system. From each load capacity test the bearing load capacity coefficient was calculated from the rule-of-thumb (ROT) model developed for foil air bearings. The test results indicate that, in terms of the load capacity coefficient, radial clearance has a direct impact on the performance of the foil air bearing. Each test bearing exhibited an optimum radial clearance that resulted in a maximum load capacity coefficient. Relative to this optimum value are two separate operating regimes that are governed by different modes of failure. Bearings operating with radial clearances less than the optimum exhibit load capacity coefficients that are a strong function of radial clearance and are prone to a thermal runaway failure mechanism and bearing seizure. Conversely, a bearing operating with a radial clearance twice the optimum suffered only a 20 percent decline in its maximum load capacity coefficient and did not experience any thermal management problems. However, it is unknown to what degree these changes in radial clearance had on other performance parameters, such as the stiffness and damping properties of the bearings.

Radil, Kevin↗
NASA NTRS2003

Monte Carlo Simulation of Sudden Death Bearing Testing

Monte Carlo simulations combined with sudden death testing were used to compare resultant bearing lives to the calculated hearing life and the cumulative test time and calendar time relative to sequential and censored sequential testing. A total of 30 960 virtual 50-mm bore deep-groove ball bearings were evaluated in 33 different sudden death test configurations comprising 36, 72, and 144 bearings each. Variations in both life and Weibull slope were a function of the number of bearings failed independent of the test method used and not the total number of bearings tested. Variation in L10 life as a function of number of bearings failed were similar to variations in lift obtained from sequentially failed real bearings and from Monte Carlo (virtual) testing of entire populations. Reductions up to 40 percent in bearing test time and calendar time can be achieved by testing to failure or the L(sub 50) life and terminating all testing when the last of the predetermined bearing failures has occurred. Sudden death testing is not a more efficient method to reduce bearing test time or calendar time when compared to censored sequential testing.

Vlcek, Brian L.↗
NASA NTRS2004

Current Status of Hybrid Bearing Damage Detection

Advances in material development and processing have led to the introduction of ceramic hybrid bearings for many applications. The introduction of silicon nitride hybrid bearings into the high pressure oxidizer turbopump, on the space shuttle main engine, led NASA to solve a highly persistent and troublesome bearing problem. Hybrid bearings consist of ceramic balls and steel races. The majority of hybrid bearings utilize Si3N4 balls. The aerospace industry is currently studying the use of hybrid bearings and naturally the failure modes of these bearings become an issue in light of the limited data available. In today s turbine engines and helicopter transmissions, the health of the bearings is detected by the properties of the debris found in the lubrication line when damage begins to occur. Current oil debris sensor technology relies on the magnetic properties of the debris to detect damage. Since the ceramic rolling elements of hybrid bearings have no metallic properties, a new sensing system must be developed to indicate the system health if ceramic components are to be safely implemented in aerospace applications. The ceramic oil debris sensor must be capable of detecting ceramic and metallic component damage with sufficient reliability and forewarning to prevent a catastrophic failure. The objective of this research is to provide a background summary on what is currently known about hybrid bearing failure modes and to report preliminary results on the detection of silicon nitride debris, in oil, using a commercial particle counter.

Dempsey, Paula J.↗
NASA NTRS2004

Consideration of Alternate Working Fluid Properties in Gas Lubricated Foil Journal Bearings

The Oil-Free Turbomachinery Program at the NASA Glenn Research center is committed to, revolutionary improvements in performance, efficiency and reliability of turbomachinery propulsion systems. One of the key breakthroughs by which this goal is being achieved is the maturation of air lubricated foil bearing technology. Through experimental testing, foil bearings have demonstrated a variety of exceptional qualities that show them to have an important role in the future of rotordynamic lubrication. Most of the work done with foil bearings thus far has considered ambient air at atmospheric pressure as the working fluid or lubricating fluid in the bearing. However, special applications of oil-free technology require the use of air at non- standard ambient conditions or completely different working fluids altogether. The NASA Jupiter Icy Moon Orbiter program presents power generation needs far beyond that of any previous space exploration effort. The proposed spacecraft will require significant power generation to provide the propulsion necessary to reach the moons of Jupiter and navigate between them. Once there, extensive scientific research will be conducted that will also present significant power requirements. Such extreme needs require exploring a new method for power generation in space. A proposed solution involves a Brayton cycle nuclear fission reactor. The nature of this application requires reliable performance of all reactor components for many years of operation under demanding conditions. This includes the bearings which will be operating with an alternative working fluid that is a combination of Helium and Xenon gases commonly known as HeXe. This fluid has transport and thermal properties that vary significantly from that of air and the effect of these property differences on bearing performance must be considered. One of the most promising applications of oil-free technology is in aircraft turbine engines. Eliminating the oil supply systems from aircraft engines will lead to significant weight and maintenance reduction. In such applications, the lubricating fluid will be high altitude air. This air will be at much lower pressure than that at sea level. Again this property change will result in a change in bearing performance, and analysis is required to quantify this effect. The study of these alternate working fluid properties will be conducted in two ways: analytically and experimentally. Analytical research will include the use of a mathematical code that can predict film thickness profiles for various ambient conditions. Estimations of load capacity can be made based upon the film thickness trends. These values will then be compared to those obtained from classical rigid bearing analysis. Experimental Research will include testing a foil bearing at a variety of ambient air pressures. The analytical and experimental data will be compared to draw conclusions on bearing performance under alternate working fluid properties.

Smith, Matthew J.↗
NASA NTRS2003

Oil-Free Turbomachinery Research Enhanced by Thrust Bearing Test Capability

NASA Glenn Research Center s Oil-Free Turbomachinery research team is developing aircraft turbine engines that will not require an oil lubrication system. Oil systems are required today to lubricate rolling-element bearings used by the turbine and fan shafts. For the Oil-Free Turbomachinery concept, researchers combined the most advanced foil (air) bearings from industry with NASA-developed high-temperature solid lubricant technology. In 1999, the world s first Oil-Free turbocharger was demonstrated using these technologies. Now we are working with industry to demonstrate Oil-Free turbomachinery technology in a small business jet engine, the EJ-22 produced by Williams International and developed during Glenn s recently concluded General Aviation Propulsion (GAP) program. Eliminating the oil system in this engine will make it simpler, lighter (approximately 15 percent), more reliable, and less costly to purchase and maintain. Propulsion gas turbines will place high demands on foil air bearings, especially the thrust bearings. Up until now, the Oil-Free Turbomachinery research team only had the capability to test radial, journal bearings. This research has resulted in major improvements in the bearings performance, but journal bearings are cylindrical, and can only support radial shaft loads. To counteract axial thrust loads, thrust foil bearings, which are disk shaped, are required. Since relatively little research has been conducted on thrust foil air bearings, their performance lags behind that of journal bearings.

Bauman, Steven W.↗