Accelerated testing of space mechanisms

This report contains a review of various existing life prediction techniques used for a wide range of space mechanisms. Life prediction techniques utilized in other non-space fields such as turbine engine design are also reviewed for applicability to many space mechanism issues. The development of new concepts on how various tribological processes are involved in the life of the complex mechanisms used for space applications are examined. A 'roadmap' for the complete implementation of a tribological prediction approach for complex mechanical systems including standard procedures for test planning, analytical models for life prediction and experimental verification of the life prediction and accelerated testing techniques are discussed. A plan is presented to demonstrate a method for predicting the life and/or performance of a selected space mechanism mechanical component

COATINGS FOR HIGH TEMPERATURE FOIL BEARINGS

ABSTRACT High operating speeds and temperatures required for advanced turbomachinery necessitate the development of bearings capable of continuous operation between 3 to 4 million DN at temperatures up to 820°C. Non-contact oil-free bearings such as compliant foil bearings, active magnetic bearings and hybrid foil and magnetic bearings are alternate solutions to the current liquid-lubricated hydrodynamic and rolling element bearings, which have limited life under these extreme conditions. A critical component in these oil-free bearings is the tribological coating system that must be used on the journal and the foil pads to ensure reliable operation during transient periods and start-stop cycles. The purpose of the present investigation was to assess the reliability of tribological coatings being implemented for a large (150 mm diameter) hybrid foil/magnetic bearing. In order to be suitable for use in large turbine engine type applications, the journal coating must accommodate the thermal and centrifugal growth experienced as well as providing the wear life and friction coefficient. Based upon the limitations identified in PS304, this coating is not yet suitable for demanding high temperature and high-speed applications. On the other hand an alternative nickel-chrome based coating applied to the foils versus a shaft with thin dense chrome or a nickel-chrome based coating a has shown excellent characteristics under conditions up to 820°C

GT2008-51514 DESIGN, DEVELOPMENT AND TEST OF A 30 KW OIL-FREE, TURBOALTERNATOR

ABSTRACT This paper describes the design procedures and testing program used in the development of a 30 kW single shaft permanent magnet turboalternator with compliant foil bearing supports. The development program included design tradeoff studies assessing generator rotor and bearing configurations, design of the turbine, and packaging of the entire system. This paper also describes the test program to assess dynamics, thermal management of the system and testing to assess power output. Test results achieved with the prototype system operating to full speed and under power generating mode will be presented

WTC2005-63951 TURBOJET ENGINE DEMONSTRATION WITH A HIGH TEMPERATURE AIR FOIL BEARING

ABSTRACT Recent tests demonstrated successful operation of a turbojet engine with a compliant foil air bearing using a new high-temperature solid lubricant coating. The hot section rolling element bearing and corresponding lubrication system were replaced with a compliant foil air bearing using a composite solid lubricant coating capable of operating at temperatures well above 650ºC (1200ºF). Detailed engine integration studies, bearing component rig testing and hot engine simulator tests were completed prior to the successful engine test. The rig and simulator tests verified high temperature capabilities of the bearing and its surface coating, the bearing journal design, bearing dynamic performance, and rotor-bearing system dynamic stability, prior to engine integration and test. Based on these preliminary efforts, the engine and bearing were assembled and tests were conducted that included over 70 start stop cycles (including hot restarts), seven simulated mission cycles and more than 14 hours of run time. The foil bearing and engine operated flawlessly throughout the test. Vibrations were very low and all temperatures and pressures were as expected. The post-test inspection revealed that the bearing, journal and coating were all in excellent condition. Keywords: compliant foil bearing, high temperature coating, solid film lubricant, gas turbine engine, and turbojet engine. INTRODUCTION Gas turbine engines having high specific thrust, high fuel efficiency, and are both durable and maintenance free are needed for a wide range of applications such as aerial targets, drones, Uninhabited Air and Air Combat Vehicles (UAV/UCAV). For example, highly efficient engines can increase UAV range and loiter time for greater data gathering. When used in drones or target systems, the quality of pilo

WTC2005-63712 MAJOR BREAKTHROUGH IN LOAD CAPACITY, SPEED AND OPERATING TEMPERATURE OF FOIL THRUST BEARINGS

ABSTRACT This paper describes major breakthroughs in foil thrust bearings achieving a thrust load capacity in excess of 570 kPa (83 psi), supersonic tip speed of 625 m/s (2050 ft/s) and temperature capability of 815 °C (1500 °F). Compliant foil bearings surpass many of the inherently show-stopping and debilitating features of rolling element bearings. Foil Bearings not only provide an environmentally-friendly, oil-free system of support, but are also well suited for high speed and extreme temperature applications such as gas turbines, compressors, turbochargers, cryogenic-turbopumps, turboexpanders, high speed motors and others. Modern foil bearings have demonstrated stable operational capabilities at super-critical speeds due to their tribodamping intrinsicality and ability to operate with any process fluid (gas or liquid). Recent developments have allowed increased operating temperatures, soaring to 815 °C and above, thus, providing a broader operational temperature range from deep cryogenic to extreme high temperatures. Foil journal bearings received more research and development attention in the past, achieving load capacity of 670 kPa (97 psi), reported by Heshmat in 1994. Foil thrust bearings' load capacity at that time was in the range of 150 kPa to 200 kPa (20 -30 psi) and their temperature capability was ambient to 150 °C (300 °F). This paper discusses a recent major breakthrough in the improvement of the load capacity, high speed capability of compliant foil thrust bearings, as well as extending their operating temperature range to 815 °C. Applying the available analytical tools and newly developed coatings, new thrust bearings have been designed with improved bearing geometry and structural compliancy. The advancement in solid lubricant coatings provided excellent tolerance to intermittent high-speed rubs, thus, making the bearings more robust against shock and extreme loadings. These advanced bearings, with outer diameters ranging from 90 mm to 230 mm, demonstrated a load capacity of 570 kPa (82.7 psi) at 200 m/s runner tip speed. This achievement constitutes two-fold improvement over any state-of-the-art hydrodynamic foil thrust bearings ever reported in the literatures and significantly expands the envelope of possible bearing applications. Improving the bearing load capacity at speeds near Mach 1.6 and higher is also discussed, as well as hydrodynamic operation of a foil thrust pad at 815 °C