Space Station lubrication considerations

Future activities in space will require the use of large structures and high power availability in order to fully exploit opportunities in Earth and stellar observations, space manufacturing and the development of optimum space transportation vehicles. Although these large systems will have increased capabilities, the associated development costs will be high, and will dictate long life with minimum maintenance. The Space Station provides a concrete example of such a system; it is approximately one hundred meters in major dimensions and has a life requirement of thirty years. Numerous mechanical components will be associated with these systems, a portion of which will be exposed to the space environment. If the long life and low maintenance goals are to be satisfied, lubricants and lubrication concepts will have to be carefully selected. Current lubrication practices are reviewed with the intent of determining acceptability for the long life requirements. The effects of exposure of lubricants and lubricant binders to the space environment are generally discussed. Potential interaction of MoS2 with atomic oxygen, a component of the low Earth orbit environment, appears to be significant

Evaluation of load tracks and wear of two sets of bearings from space shuttle main engine high pressure oxygen turbopumps

Bearings supporting the rotor in the High Pressure Oxygen Turbopump (HPOTP) were examined. The No. 1 bearings from both units were in good condition and had successfully completed 5000 seconds of operation. The No. 2 bearings, which were in service the same length of time, were significantly degraded in the form of ball wear, race pitting, and damage from high axial loads. The No. 3 and 4 bearings were in generally acceptable condition. The general conclusion from the examinations was that improved cooling on the No. 2 bearings and further improvements in controlling axial and radial load would likely result in the HPOTP meeting the qualification test results

Replacement bearing for Rocketdyne SSME HPOTPs using alternate self-lubricating retainer materials

Research was conducted to develop replacement bearings for the Rocketdyne Space Shuttle main engine (SSME) high pressure oxidizer turbopumps (HPOTPs). The replacement bearings consisted of standard balls and races with a special Battelle Self-Lubricating Insert Configuration (BASIC) retainer. The BASIC retainer consists of a phosphor bronze housing with inserts consisting of a polytetrafluoretheylene (PTFE) and bronze compound. The PTFE contacts the balls and the land guiding surface on the outer race. A PTFE transfer film is formed on balls and races, which lubricates the critical interfaces. The BASIC retainer is a one-to-one replacement for the current Armalon retainer, but has superior lubricating properties and is stronger over the broad temperature range anticipated for the HPOTP bearings. As a part of the project 40 sets of balls and races (two sizes) and 52 BASIC retainers were shipped to NASA/MSFC

Evaluation of SSME high pressure liquid oxygen turbopump bearings

Examination of the bearings produced conclusive evidence that a very high axial load was applied to bearing 8517903 during a significant portion of the service time. The high loads caused serious ball and race wear and surface fatigue pitting. In all likelihood, continued operation of this bearing with the high axial load would have caused increasing deterioration and catastrophic failure. In contrast, bearing 8517900 showed much less deterioration and probably had experienced only the axial loads deliberately applied by the preload spring. Bearing 8517900 represents the best-case operation with the loads controlled to the levels intended in the design. Fatigue life calculations on bearing 8517903 with an axial load of 27,000 N showed the intolerance of the bearing to such load levels

Rolling element bearings in space

Some of the advances in tribology that have been associated with aerospace mechanisms are discussed. The needs of aerospace have been the dominant forces leading to improvements in understanding and applying tribology technology. In the past two decades improvements in understanding bearing torque, elastohydrodynamic lubrication, lubricant distribution, cage stability, and transfer film lubricants have been made. It is anticipated that further developments will be made in response to future aerospace requirements

Transfer film evaluation for shuttle engine turbopump bearing

A series of low speed experiments to evaluate the possible occurrence of transfer film lubrication and the effectiveness of burnished films in the shuttle spacecraft main engine thrust bearings were conducted. No evidence of transfer film lubrication was evident, although this could have been the result of the (used) condition of the bearing. Burnished films of either Teflon or Rulon were found to greatly enhance the performance of the bearing. Crush load experiments indicated that the bearing ultimate load capability is on the order of 489,000 N (110,000 pounds). The effect of ball (as well as race) burnishing techniques on bearing performance, different types of burnished films, and transfer film formation are suggested for further study

Study of rolling-contact phenomena in magnesium oxide

Study of rolling contact deformation phenomena in magnesium oxide single crystal

Evaluation of shuttle turbopump bearings

Because the high pressure turbopumps used on the space shuttle main engine (SSME) are high speed machines and rotor dynamics analysis of these units is very complicated, it was considered necessary to verify calculated turbomachinery shaft bearing loads by analysis of ball bearing load tracks. This report presents the methods used and the results of load track analysis on one set of bearings removed from a high pressure liquid oxygen turbopump which had been subjected to SSME static firing tests. This type of analysis was found useful in determining bearing operating conditions and for verifying rotor dynamics computer models

Optimization of daytime fuel consumption for a hybrid diesel and photovoltaic industrial micro-grid

2017 Spring.Includes bibliographical references.The work to be presented will examine the optimization of daytime diesel fuel consumption for a hybrid diesel and photovoltaic (PV) industrial micro-grid with no energy storage. The micro-grid utilizes a control system developed to forecast PV transients and manage the diesel generators providing electrical supply to the micro-grid. The work focuses on optimization of daytime fuel consumption when PV generation is available. Simulations were utilized to minimize diesel consumption while maintaining secure operations by controlling both PV curtailment and diesel generation. The control system utilizes a cloud forecast system based upon sky imaging, developed by CSIRO (Australia), to predict the presence of cloud cover in concentric "rings" around the sun's position in the sky. The control system utilizes these cloud detections to establish supervisory settings for PV and diesel generation. Work included methods to optimize control response for the number of rings around the sun, studied the use of two different sizes of generators to allow for increased PV utilization, and modification of generator controller settings to reduce fault occurrence. The work indicates that increasing the number of rings used to create the PV forecast has the greatest impact on reducing the number of faults, while having a minimal impact on the total diesel consumption. Additionally, increasing the total number of generators in the system increases PV utilization and decreases fuel consumption

Lubricant Selection Manual, Phase 3

Future spacecraft must be designated to operate for very long time periods in space. For example, a target goal for the Space Station is 30 years of operation. Although the actual life may be significantly less than this optimistic goal, the life will certainly be a critical issue in design. The bearings on primary components such as the alpha and beta joints must obviously be designed and lubricated with the objective of optimum performance life. In addition to these joints, there will be numerous other tribological (rubbing or rolling) interfaced that will be required to function for the life of the spacecraft. A major key to adequate performance of tribological interface is proper lubrication. Lubricants can be divided into two basic classes: solid films and liquids. Both types have been used extensively in space applications. Both have advantages and disadvantages that must be carefully considered in their selection. The purpose here is to summarize selection criteria for liquid and solid lubricants applied to long-life spacecraft