Tribology & Mechanical ComponentsBranch Overview

Dr. Robert F. Handschuh

NASA Glenn Research Center

Cleveland, Ohio, U.S.A.

Abstract:

An overview of NASA Glenn Research Center's Tribology & MechanicalComponents Branch is provided. Work in space mechanisms, seals,oil-free turbomachinery, and mechanical components is presented.An overview of current research for these technology areas iscontained in this overview.

https://ntrs.nasa.gov/search.jsp?R=20100041305 2018-02-01T03:39:09+00:00Z

Tribology &Mechanical ComponentsBranch Overview

Dr. Robert F. HandschuhNASA Glenn Research Center

Cleveland, Ohio, U.S.A.

Topics

• View from 30,000 feet• Structures and Materials Division• Tribology &Mechanical Components Branch• Branch teams• Oil-free bearing research activities• Tribology activities• Seals Team activities• Drive system activities• Summary

NASA Glenn Research Center

AeroshellsTPS; Cooled strs.Cryogenic tanksNacellesCombustorsEngine fan systemMechanismsOil-Free enginesInjectorsHigh-power motorsSpace lubricantsProtective CoatingsSensorsThermoelectrics

Surface mobility systemsNozzlesIn-space & on-surface modulesRotor discs and systemsTurbine vanesEnergy absorbing systemsMechanical drive systemsHuman health systemsThrustersBearings and flywheelsSolid oxide fuel cells, batteriesHigh temp. and cryogenic sealsPorous membranesBN nanotubes

ore R&T Capabilities

Materials and Structures Division CapabilitiMateria ls and Structures Division

Propulsion and Power System Components

Probabilistic methodsMechanical power transferImpact dynamicsStructural mechanicsMaterial modelingMaterial characterizationFunctional materialsMetallic alloysComputational materialsSurface scienceMaterials science

Matl. and strl. ConceptsHealth prognosticsBlast mechanicsStructural dynamicsJoining technologyFailure and damage growthProcessing technologiesShape memory alloysProtective coatingsExtreme environment effectsHigh temperature chemistry

Design technologyExperimental methodsMeasurement technologyAeroelasticityDurability and lifeFatigue and fractureHigh temp. and cryo sealsCeramic materialsMultifunctional MaterialsLubricant chemistryFriction and wear

rTribology & Mechanical Components Branch

“NASA ʼs one-stop-shop for all itsmechanisms & lubrication needs”

Branch Organization:

â Oil-Free Turbomachinery – Dr. Chris DellaCorte

â Space Mechanisms & Lubrication – Dr. Phil Abel

â Aerospace Seals – Dr. Bruce Steinetz

â Aero Drive Systems – Dr. Robert Handschuh

Heat Shield

Interface Seal

Docking Seal

• Space habitat seals for extreme environments• Structural / thermal protection seals• Non-contacting turbine seals

• Gear fatigue research• High speed gear lubrication• Drive system diagnostics• Fatigue crack modeling• Dynamic mechanical components• Rotorcraft transmission systems• Advanced rolling element andwave bearing technologies

• Tribology & Mechanical Components Branch

Oil-Free Turbomachinery

Space Mechanisms & Lubrication

From basicresearch to

ppa lication

• Aero / Space application• World-leading bearing experts• Advanced modeling methods• Foil bearing predictive design

Aerospace Seals Research

• Accelerated space lubricant life testing under vacuum• New mechanism concepts for planetary environment• New space lubricant development• Terramechanics modeling & testing for efficient wheels

Aero Drive Systems

TGIR Award for Level I Milestone:“Core Hot Bearing Tests” (OFTET)

Foil air bearingsCAD

Oil-Free Turbomachinery

Oil-Free enabling technologies ?

r

PM304 bushings forindustrial furnaces

and valves

P10", Oil-Free Key Facilities & Capabilities

ambient pressure test rig

Coating depositionresearch facility

MicroTurbineproof-of-concept& environmental

durability testfacility

Hot high-speedShaft rotordynamicthrust foil bearing rigsimulator test facility

Space Tribology & Materials

BEARING RIGFull Scale

Bearing Tests

SPIRAL ORBIT TRIBOMETERAccelerated Lubricant Life

Testing Under RealisticConditions

VACUUM 4-BALLAccelerated Bulk Property

Testing of Lubricants .

Other Facilities:*Vapor Pressure of Fluids*Radiation Damage of

Polymers

Heating soot to hightemperatures in aninert atmosphere

graphitizes thecarbon

to form nano-onions.

Nano-Structured Lubricants for Tribology

Carbon nanostructure transformation by industriallyscalable GRC developed process

Addition of a small amount of nano-onions to oil improved the lifetime by a factor of 8x while decreasing the friction by a factor of 2.6

Spiral Orbit Tribometer (SOT) SOT Nano-grease Friction TracesRotating plate 1000 moo 3000 moo(tilted up for clarity) - I Rotation u 3

Ball orbit -^ '^Spiral orbit Nano-onions mixed with oil ox®

: ^ (I^'yt

143AB) form a nano-grease. Whentested in the SOT, which mimics themotion of a ball bearing, significantfriction and lifetime improvements o.

in air are realized.

of

Orbits

Surface Science Tools

Raman

Dft„ema.ek-91- --p-dto aiff—t c Chermam b—fi w

.m.s.e rwtn mir.na my ccz aawRedNbnP^MYn.gWan: CF3 V.G.

. w^.C.F^ 0 FT-IR

Depth (,,Metres)

Auger

0 1 2 3,um

AFM

Thermal barrier for Shuttle andAtlas V SRM nozzle joints

NASA GRC Seal Team

NASA GRC Seal Team contributions haveinfluenced several flight projects:

- Shuttle main landing gear door environmental seals- Thermal barrier (braided carbon fiber rope) for

nozzle joints of Shuttle and Atlas V SRM’s

ShelMechanical seal attac

Shelf/sealing surface:AETB-8 ,tile ;on'aluminstructure

NASA GRC Seal Team Overview

• NASA GRC Seal Team contributions have influencedseveral flight projects:– X-38 rudder/fin seals– X-37 flaperon seals

Low Impact Docking System (LIDS)

• LIDS is a system under developmentby NASA JSC designed to:

– Provide gender-neutral(androgynous) interface permittingdocking and berthing between anytwo space vehicles

– Reduce impact loads between twomating space craft

– Become new Agency standard fordocking/berthing systems

alignment

Seal Test Facilities

Spiral Bevel / Face Gear Test Facilities Gear Noise / Dynamics Test Facility

Drive System Test Facilities

Spur Gear Fatigue Test Rigs

Split Torque Test Facility

OH-58 Transmission Test Facility

High Speed Helical Gear Train Facility

Drive System Analytical Capabilities

Finite Element BasedStructural - Thermal

Planetary Gear Dynamics

99

98

97

EfÞciency(%)

96

95

94

1000

/ 0 Experimental Results 12500 RPMd —,0— Experimental Results 15000 RPM

• •^^• Analytical Prediction 12500 RPM• • y* • Analytical Prediction 15000 RPM

2000 3000 4000 5000

Gearbox Power (hp)

High Speed Gearing ResultsNASA - ARL/VTD - Bell Helicopter

100 -

_ ___ = -'" Bearing Losses80

Total` _...._.._.....

Losses 60 Gear Meshing Losses

(hp)

40

WIndage Losses20

08000 10000 12000 14000 16000 18000 20000

Input Torque (in*lb)

P Windage = C3 C ' N 2.85D4.7v 0.15

70

------------ - f Dawson Model 1% Lube-60 ----------------- —v— Dawson Model 0.75% Lube -------- --- -

• ---f Daswson Model Lube •:--_-_-_ - ------_-- •• -•••_-_-_-_-_-_-_

- • %% Dawson Model 0.25% Lube

• -50 • • • --- ,------ • —^ Dawson Model - No Lube '------ . "'""

Windage .........::-- --,..........._......::::::::::: .... .....'Power 40-..

- ---, .. ............. :... ........- ,Loss -

- --- --------(hp) 30 ........... .. ... ......... _ ................... . .....,- - ,..

-------- ---- -------tom:........ ---- --

20

10 _ ^.....- —--------------...... .. k - -

06000 8000 10000 12000 14000

Input Shaft Speed (RPM)

Condition Based Maintenance

Objectives: Increase reliability and decrease false alarms formechanical component diagnostics. Demonstrate integration of oildebris and vibration based damage detection techniques results inimproved capability.

Approach:Instrument and monitor all GRC gear fatigue test facilities and workwith other govt. agencies, university, and industry

Condition Based Maintenance

Vibration Techniques

151 ^^15 (FM4,NA4) and Oil

,j Debris

^q 10 7 f J^ 11 S 10^

RW

f i,

r +r r °

r.-- n • ^ ^ n ^

^ 500 100D 1500 2000 2500 3000 3.50 1

Reading Number 1 - r

0.9 DamageCLa 0.8

0.7

0.6

7@- 0.5 Inspect0.4

Output of 0.3

0.2

Fuzzy Logic Model 0. 1-, Normal0

0 500 1000 1500 2000 2500 3000 3500

Reading Number

Test Facility

Wave Bearing Technology

Bearing Concept

• Improved stability and cooling• Ability to tailor stiffness and damping• Use of hard sleeves

Fracture Toughness

Ferrium C69 AISI 9310

Surface Fatigue Results

Gear Number Number of Median lifeMaterial of tests (million

failures completed cycles)

AMS 15 21 1346308B[Ref. 10]

AISI 25 33 2009310[Ref. 13]

Ferrium 5 10 361® C69[presentstudy]

Advanced Gear Material

b, e^07 o4y1' r r,' • Excellent Contact Fatigue• Poor Fracture Toughness

Space Mechanism Wear

Dither Damage Assessment

650

600

550

500

450

400

350

300

250

200

Bending

Stress

Index

(ksi)

Low Cycle Bending Fatigue

1e+0 1e+1 1e+2 1e+3 1e+4 1e+5

Cycles

Tilt Axis Combiner GearboxGearbox

ReductionGearbox

rCivil Tiltrotor Drive System Configuration

To Mid-WingGearbox Variable /Multi-Speed

n Gearbox

Hover Ratio 131.4: 1 Forward Flight Ratio 243.6 : 1

GearPerformance

Penn State Univ. - NASA NRA R&D

RotorcraftConfiguration —^ Assemble Model

Flight r—— ——^Condition .

I IPilot Flight Control System

Inputs System Model .

I II I

Powertrain •

Control Law

I I

SystemDynamics

Subsonic Rotary Wing: High FidelityDesign Tools

Windage Test Facility, NASA-GRC

Drive Motor

Speed Increasing'- Gearbox -

Dr. Robert F. Handschuh, Army Research Lab, NASA - GlennMark A. Stevens, NASA Glenn Research Center

Input Output

In-Line Two Speed Advanced RC Drive Systemr

J Wet / Dry Clutch

Over-Running Clutch

High Speed Operation (hover): Wet/ Dry Clutch engaged, Over-Running Clutch over-runningLow Speed Operation (cruise): Wet/ Dry Clutch disengaged, Over-Running Clutch driving

Dr. Robert F. Handschuh (October 2007)

Flywheel

DriveMotor

Flywheel

TorsionalLoad

Variable / Multi-Speed Drive FacilityConcept

TransmissionConcept

Summary

• Four main focus areas in the drive system area:* Oil-Free Turbomachinery* Tribology –Surface Science* Seals –Static and Dynamic* Drive System Technologies

• Currently conduct /manage research within ourcenter as well as at contractor and university locations

• Involved in analytical and experimentaldevelopments

• Work closely with the space &aerospace industry,other government agencies / NASA centers, NESCÉ.