Top Foil Research Articles

Low-friction wear-resistant coatings for high-temperature foil bearings

Compliant foil bearings offer many advantages over rolling element bearings in high-speed and high-temperature applications. However, implementation of foil bearings in these applications requires development of solid lubricant coatings that can survive the severe operating conditions encountered at high speeds and high temperatures. The objective of this paper is to present results on development of an advanced coating system for use with compliant foil bearings that permits higher operating speeds and temperatures. In order to evaluate the coating performance and to select the best coating combination for implementation, tests were conducted using a high-temperature, high-speed tribometer. In these tests, Inconel test substrates, representative of a portion of a foil bearing, were coated with several different Korolon TM coatings. The counterface disks were coated with a dense chrome, plasma sprayed PS304, hard chrome and Korolon TM 1350B. Each test was conducted for 500 start–stop cycles up to 810 °C foil pad temperature under 13.8 kPa normal loading. The test results confirmed the excellent tribological behavior of Korolon TM coatings for high-speed, high-temperature foil bearing applications. While the tribological behavior of Korolon TM coatings were determined to be a function of temperature, in most cases a minimum coefficient of friction less than 0.1 was observed during startup/shutdown periods. Based on the measured coefficient of friction and post-test visual inspection of the mating surfaces, the hard chrome coating proved unacceptable for high-temperature applications due to extensive surface cracking. The other disk coatings exhibited excellent tribological performance. Following these tests, a foil journal bearing was designed and a composite coating consisting of Korolon TM 1350A with an overcoat of Korolon TM 800 was applied to the bearing top foil; and a dense chrome coating was applied to the journal surface. The foil bearing and journal were installed in a 240-lb thrust turbojet engine and operated successfully to 54,000 rpm for over 70 start–stop cycles and 14 h.

MULPEX: A compact multi-layered polymer foil collector for micrometeoroids and orbital debris

Detailed studies of preserved hypervelocity impact residues on spacecraft multi-layer insulation foils have yielded important information about the flux of small particles from different sources in low-Earth orbit (LEO). We have extended our earlier research on impacts occurring in LEO to design and testing of a compact capture device. MUlti- Layer Polymer EXperiment (MULPEX) is simple, cheap to build, lightweight, of no power demand, easy to deploy, and optimised for the efficient collection of impact residue for analysis on return to Earth. The capture medium is a stack of very thin (8 and 40 μm) polyimide foils, supported on poly-tetrafluoroethylene sheet frames, surrounded by a protective aluminium casing. The uppermost foil has a very thin metallic coating for thermal protection and resistance to atomic oxygen and ultra-violet exposure. The casing provides a simple detachable interface for deployment on the spacecraft, facing into the desired direction for particle collection. On return to the laboratory, the stacked foils are separated for examination in a variable pressure scanning electron microscope, without need for surface coating. Analysis of impact residue is performed using energy dispersive X-ray spectrometers. Our laboratory experiments, utilising buck-shot firings of analogues to micrometeoroids (35–38 μm olivine) and space debris (4 μm alumina and 1 mm stainless steel) in a light gas gun, have shown that impact residue is abundant within the foil layers, and preserves a record of the impacting particle, whether of micrometer or millimetre dimensions. Penetrations of the top foil are easily recognised, and act as a proxy for dimensions of the penetrating particle. Impact may cause disruption and melting, but some residue retains sufficient crystallographic structure to show clear Raman lines, diagnostic of the original mineral.

An Experimental Investigation into the Temperature Profile of a Compliant Foil Air Bearing

A series of tests was performed to determine the internal temperature profile in a compliant bump-type foil journal air bearing operating at room temperature under various speed and load conditions. The temperature profile was collected by instrumenting a foil bearing with nine type-K thermocouples arranged in the center and along the bearing's edges in order to measure local temperatures and estimate thermal gradients in the axial and circumferential directions. To facilitate the measurement of maximum temperatures from viscous shearing in the air film, the thermocouples were tack-welded to the backside of the bumps that were in direct contact with the top foil. The mating journal was coated with a high-temperature solid lubricant that, together with the bearing, underwent high-temperature start-stop cycles to produce a smooth, steady-state run-in surface. Tests were conducted at speeds from 20 to 50 krpm and loads ranged from 9 to 222 N.The results indicate that, over the conditions tested, both journal rotational speed and radial load are responsible for heat generation with speed playing a more significant role in the magnitude of the temperatures. The temperature distribution was nearly symmetric about the bearing center at 20 and 30 krpm but became slightly skewed toward one side at 40 and 50 krpm. Surprisingly, the maximum temperatures did not occur at the bearing edge, where the minimum film thickness is expected, but rather in the middle of the bearing, where analytical investigations have predicted the air film to be much thicker. Thermal gradients were common during testing and were strongest in the axial direction from the middle of the bearing to its edges, reaching 3.78° C/mm. The temperature profile indicated the circumferential thermal gradients were negligible.

Suppression of Subsynchronous Vibrations Due to Aerodynamic Response to Surge in a Two-Stage Centrifugal Compressor with Air Foil Bearings

An investigation was conducted on the suppression of subsynchronous vibrations due to aerodynamic response to surge in a two-stage centrifugal compressor with air foil bearings. Unsteady aerodynamic response to surge caused excessive subsynchronous shaft vibration which might result in reduced bearing life. Notably, subsynchronous vibrations associated with rigid mode frequencies were more severe than any other subsynchronous vibrations. The objective was to develop rotordynamic stability near the surge line in a two-stage compressor by the modification of bearings into high damping foil bearings. Viscoelastic foil bearings, which consist of a viscoelastic top foil supported by a series of bump foils, were adapted to replace bump type foil bearings in a two-stage compressor. Investigations were made in the form of a compressor operating test near the surge line with the conventional bump foil bearing and the viscoelastic foil bearing respectively. Testy results showed the effectiveness of the viscoelastic foil bearing for suppressing the subsynchronous vibrations, including subsynchronous vibrations associated with rigid mode frequencies of the shaft. Thus, rotordynamic stability was improved with a viscoelastic foil bearing, which has enhanced damping characteristics near the surge line. Scheduled for Presentation at the 58th Annual Meeting in New York City April 28–May 1, 2003

The Effect of Journal Roughness and Foil Coatings on the Performance of Heavily Loaded Foil Air Bearings

Foil air bearing load capacity tests were conducted to investigate if a solid lubricant coating applied to the surface of the bearing's top foil can function as a break-in coating. Two foil coating materials, a conventional soft polymer film (polyimide) and a hard ceramic (alumina), were independently evaluated against as-ground and worn (run-in) journals coated with NASA PS304, a high-temperature solid lubricant composite coating. The foil coatings were evaluated at journal rotational speeds of 30,000 rpm and at 25 °C. Tests were also performed on a foil bearing with a bare (uncoated) nickel-based superalloy top foil to establish a baseline for comparison. The test results indicate that the presence of a top foil solid lubricant coating is effective at increasing the load capacity performance of the foil bearing. Compared to the uncoated baseline, the addition of the soft polymer coating on the top foil increased the bearing load coefficient by 120 percent when operating against an as-ground journal surface and 85% against a run-in journal surface. The alumina coating increased the load coefficient by 40 percent against the as-ground journal but did not have any effect when the bearing was operated with the run-in journal. The results suggest that the addition of solid lubricant films provide added lubrication when the air film is marginal, indicating that as the load capacity is approached foil air bearings transition from hydrodynamic to mixed and boundary lubrication. Presented at the 56th Annual Meeting in Orlando, Florida May 20–24, 2001

Thermal Features of Compliant Foil Bearings—Theory and Experiments

The paper presents an analytical and experimental investigation aimed at eliciting the thermal characteristics of air lubricated compliant foil bearings. A Couette Approximation to the energy equation is used in conjunction with the compressible Reynolds equation to obtain a theoretical temperature distribution in the air used as a lubricant. The effect of temperature on the thermal properties of the working fluid is included. In parallel, an experimental program was run on a 100 mm diameter foil bearing operating at speeds up to 30,000 rpm employing cooling air across the bearing. The temperature rise of the cooling air provided an indication of the amount of heat energy conducted across the top foil of the bearing from the hydrodynamic film. The temperatures resulted from some tests are compared with the temperatures predicted by the analysis, and maximum over-prediction of about 19 percent was obtained. This simplified approach provides us with reasonably predicted temperatures. By comparing the theoretical heat dissipation obtained from the analytical predicted temperatures with the amount of heat carried away by the cooling air it was possible to arrive at the relative quantities of heat transferred from the bearing by convection via side leakage and by conduction via the top foil. From these comparisons it was deduced that about an average of 80 percent of the heat energy is carried away by conduction. The transient temperatures of the foil bearing in conducted tests for various speeds and loads are also presented.

On the Performance of Hybrid Foil-Magnetic Bearings

Recent technological advancements make hybridization of the magnetic and foil bearings both possible and extremely attractive. Operation of the foil/magnetic bearing takes advantage of the strengths of each individual bearing while minimizing each other’s weaknesses. In this paper one possible hybrid foil and magnetic bearing arrangement is investigated and sample design and operating parameters are presented. One of the weaknesses of the foil bearings, like any hydrodynamic bearing, is that contact between the foil bearing and the shaft occurs at rest or at very low speeds and it has low load carrying capacity at low speeds. For high speed applications, AMBs are, however, vulnerable to rotor-bending or structural resonances that can easily saturate power amplifiers and make the control system unstable. Since the foil bearing is advantageous for high speed operation with a higher load carrying capacity, and the magnetic bearing is so in low speed range, it is a natural evolution to combine them into a hybrid bearing system thus utilizing the advantages of both. To take full advantage of the foil and magnetic elements comprising a hybrid bearing, it is imperative that the static and dynamic characteristics of each bearing be understood. This paper describes the development of a new analysis technique that was used to evaluate the performance of a class of gas-lubricated journal bearings. Unlike conventional approaches, the solution of the governing hydrodynamic equations dealing with compressible fluid is coupled with the structural resiliency of the bearing surfaces. The distribution of the fluid film thickness and pressures, as well as the shear stresses in a finite-width journal bearing, are computed. Using the Finite Element (FE) method, the membrane effect of an elastic top foil was evaluated and included in the overall analytical procedure. Influence coefficients were generated to address the elasticity effects of combined top foil and elastic foundation on the hydrodynamics of journal bearings, and were used to expedite the numerical solution. The overall program logic proved to be an efficient technique to deal with the complex structural compliance of various foil bearings. Parametric analysis was conducted to establish tabulated data for use in a hybrid foil/magnetic bearing design analysis. A load sharing control algorithm between the foil and magnetic elements is also discussed. [S0742-4795(00)01201-1]

Analysis of Gas Lubricated Foil Thrust Bearings Using Coupled Finite Element and Finite Difference Methods

Load performance of gas lubricated, compliant surface foil thrust bearings has an interlocking relationship with the compliance of the bearing and hydrodynamics of convergent wedge surface. Compliance of the bearing consists of supporting spring elements (elastic foundation) and a smooth elastic top foil. In this paper, a class of gas lubricated foil thrust bearings has been investigated analytically utilizing a novel approach which combines Finite Difference (FD) and Finite Element (FE) methods. Solution of the governing hydrodynamic equations dealing with compressible fluid is coupled with the structural resiliency of the foil bearing surfaces. FD method is utilized for hydrodynamic analysis while FE is used to model structural resiliency. Influence coefficients were generated to address the elasticity effects of combined top foil and elastic foundation on the hydrodynamics of thrust bearing, and were used to expedite the numerical solution. Within 2 to 3 iterations the convergence criterion was reached. The overall program logic proved to be an efficient technique to deal with the complex structural compliance of various foil bearing. Case study has been conducted and sample solutions are provided. Unlike prior analytical investigations, the essential effect of the top foil on the performance of the bearing has been elucidated. [S0742-4787(00)02501-7]

Compliant Foil Bearing Structural Stiffness Analysis: Part I—Theoretical Model Including Strip and Variable Bump Foil Geometry

This paper presents a theoretical model of corrugated foil strip (bump foil) deformation in compliant foil bearings and dampers. The friction forces between bump foils and the housing or the top foil, local interaction forces, variable load distributions, and bump geometries are taken into consideration. Following the trend of earlier published experimental data, the bumps near the fixed end have a much higher predicted stiffness (lower deflection) than those near the free end. Higher friction coefficients tend to increase stiffness and may pin down bumps near the fixed end. An increase in the friction coefficient between the top foil and the bump is a more effective method of achieving both Coulomb damping and higher stiffness. In addition to bump geometry, the load distribution profile greatly influences bump stiffness. A follow-up paper will present the experimental verification and discuss the comparison between theoretical and experimental results.

A technique for the determination of the thickness of TEM foils

A technique is described by which the thickness of TEM foils may be measured. The technique requires the top and bottom foil surfaces to be intersected by precipitates, or some other visible defect such as stacking faults or slip traces, on the {111} matrix planes. This technique requires no assumptions to be made regarding the angle between the normal to the foil surface and the electron beam direction, a parameter that had to be considered in previous methods.

The effect of particle height on the analysis of precipitates in alloy foils

The relative height of small second-phase particles within a thin alloy foil can have a significant effect on the characteristic x-ray signal obtained from the particle during microanalysis in a STEM. Figure 1 illustrates this for the case where the energy dispersive x-ray detector attached to the STEM views the sample on the side entered by the incident electron beam. If the particle is located below the top foil surface, as in Fig. 1a, beam spreading may reduce the total current striking the particle, thereby reducing the generated signal. The x-ray spectrun of the particle may be further reduced and distorted by matrix absorption en route to the detector. Clearly the optimal position for microanalysis is shown in Fig. 1b: The particle to be analyzed should be on the sample surface facing the beam and x-ray detector.These considerations were demonstrated in an experiment performed on a sample of Alloy 800, a high-allqy austenitic steel. The STEM used was a JEQL 200CX operated at 200kV. The second phase particles (Ti-carbides in this case) in the Alloy 800 electropolished at different rates from the matrix during sample preparation. Those particles located at the surface of the foil after thinning therefore produced surface relief and could be imaged using the secondary electron detector on the STEM. Figure 2 shows a mixed secondary electron/transmitted electron image of the TiC particles analyzed for this experiment.