32 nd Turbomachinery Research Consortium Meeting Tribology Group

32 nd Turbomachinery Research Consortium Meeting Tribology Group Rotordynamics Laboratory Luis San Andres Mast-Childs Professor Turbomachinery Laboratory Mechanical Engineering Department Texas A&M University May 2012 http: //rotorlab. tamu. edu 1

Tribology Group Mission: To advance state of the art in fluid film bearings for high performance turbomachinery Types of funded research projects: • Engineering science fundamentals & development of computational engineering tools, • Experimental – Bearing & Seal parameter identification • Test-product verification & design validation • Education 2

Students Tribology Group Top: Botto m Feng Yu Owen Jose Zhan Hernand g ez Yujiao Alain Tao Anderso n Sung. Hwa Jeung Joshua Norswort hy Gary Bradley Stephani e Simersk ey Qing Liu 3

Analysis/test product & design validation Thermal energy transport for bearing systems in turbochargers Honeywell Turbocharging Technologies (09/10 -09/12) $ 208 k Efficient energy transport by oil flow determines TC performance 4

Analysis: product verification & design validation Modeling thrust foil bearings for PV & CV Turbos Borg-Warner (2011 -2012) $ 90. 4 k Needs: more reliable & + power efficient TCs, lighter oils (0 -5 W) and higher inlet temperatures (~150 C). Oil free TCs dispense with contaminated engine oil to increase reliability. Deliverable: Predictive tool for ready integration into B&W engineering design flow. Test validation at B&W (Germany) 5

2010 -12 TRC funding Measurement of leakage in a novel all metal noncontacting annular seal at high temperature TRC (10 -12) $ 74. 8 k (2 years) HALO™ Seal Labyrinth seal High temperature seal test rig (300 C=572 F) Project progress status follows HALOTM seal 6

2010 -12 TRC funding Computational model for tilting pad journal bearings TRC (10 -12) $ 70. 4 k (2 years) Carter & Childs, ASME GT 2008 -50069 Technical presentati on follows For high load bearings (> 150 psi), improve correlation to experimental force coefficients by adding pad-pivot flexibility and fluid energy transport & thermal effects Test TAMU TPB (Wilkes) New Model YY New Model XX XX Test rotor speed 13. 1 krpm YY 7

2011 -12 TRC funding Automated Analysis of XLTRC 2 Time Transient Responses in Nonlinear Rotor Bearing Systems TRC (11 -12) $ 34. 8 k (1 year) Technical presentation follows Manage output of XLTRC 2 time response of NL rotor-bearing motions & characterize frequency and modal content 8

2011 -12 TRC funding: Gas bearings for MTM Metal Mesh Foil Bearings: Operation at High Temperature TRC (11 -12) $ 36. 6 k (1 year) State of the art predictive tools benchmarked to test data Technical presentation follows. Report TRC-BC 001 -12 Oil free TM research past funding TRC (2003 -2009) $ 312 k NSF (2003 -2006) $ 255. 5 k NASA GRC (2007 -2009) $ 284. 6 k Capstone (2007) $ 64. 7 k 9

2011 -12 TRC funding: Linear/Nonlinear SFDs SFD TESTING & ANALYTICAL METHODS DEVELOPMENT Large load (500 lbf) SFD test rig Pratt & Whitney (08/08 -12/12) $ 436 k TRC (12) $ 39. k (1 year) Static loader Shaker assembly (Y direction) Technical presentation follows Report. TRC-SFD-01 -12 Shaker assembly (X direction) SFD test bearing 10

Other industrial project Computational analysis of textured gas face seals for steam turbines CIATEQ A. C. (Mexico) (2010 -12) Sponsors 1 grad student Replace carbon rings to increase turbine reliability. Typical steam turbine for lubrication system mechanical drive Non-contacting gas face seal with textured pattern Model novel textured face seal geometries and GUI for whole seal cartridge 11

Invited submissions (May 31) NSF China-TAMU program Xi’an Jiaotong University • DESIGN AND OPERATION OF LUBRICATED HIGH SPEED SPINDLES: COUPLED SYSTEM THERMO MECHANICAL AND DYNAMICS EFFECTS • NOVEL THRUST FOIL BEARINGS FOR OIL-FREE MICROTURBOMACHINERY More collaborative research programs expected with Asian OEMs, and KOSEF (Korea Science Foundation), NSF-China, CONACYTMexico, Brazil Education Ministry. 12

The rankings 2012: 15 th among all institutions 13

Tribology Group Students • • Prepared for global competency Learn communication skills (written & oral) Training in teams that work and deliver Ready for open-ended multidisciplinary problems with no unique answer Experience in research tied to industrial needs Learn of compelling need for professional integrity Do more with less Do more with nothing! Diversity students 2012 2 Ph. D (1 F) 6 MS (1 F, 1 H) 2 UGS (1 F, 2 AM) Graduating 08/2012 Ph. D Thomas Chirathadam (Sw. RI) MS Yujiao Tao MS Jose Hernandez (CIATEQ, Mx) MS Feng Yu 14

Performance Funding 2010 -2012 $ 208. 3 k (Honeywell) + 97. 2 k (Pratt & Whitney) + 90. 4 k (Borg Warner) + 146. 2 k (TRC-2011) 542. 1 k + $ 68. 0 k software licenses Research expenditures $ 246. 4 k (FY 11) $ 182. 2 k (FY 12) 15

Scholarship 08 09 10 11 12 Total 2011 -2012 Journal (peer reviewed) 5 6 11 6 2 8 Conference (peer reviewed) 6 7 7 5 5 10 Conference (NOT peer reviewed) 2 2 2 1 1 3 3 4 4 Book Chapters Accepted/awaiting publication • 2011 BEST Rotordynamics Paper Award – IGTI Structures and Dynamics Committee San Andrés, L. , and Delgado, A. , “A Novel Bulk-Flow Model for Improved Predictions of Force Coefficients in Grooved Oil Seals Operating Eccentrically, ” ASME Paper GT 2011 -45274. • 2010 Best Paper Award for ASME Journal of Tribology (2011 IJTC Conference, LA) Kim, T. H. , and San Andrés, L. , 2010, “Thermohydrodynamic Model Predictions and Performance Measurements of Bump-Type Foil Bearing for Oil-Free Turboshaft Engines in Rotorcraft Propulsion Systems, ” ASME Journal of Tribology, 132, p. 011701 Total: FIVE Best paper awards 2002 -2012 16

2012 TRC reports TRC-SFD-01 -12 Force Coefficients for a Large Clearance Open Ends SFD with a Central Feed Groove: Test Results and Predictions TRC-BC 001 -12 Measurements of Rotordynamic Response in a High temperature Rotor Supported on two Metal Mesh Foil Bearings In the works after n+1 revisions Summer 2012: Reports on computational model for tilting pad bearings (Y. Tao, M. S. Thesis) and NL rotordynamics XLTRC 2 modeling (Q. Liu) 17

2012 TRC proposals # years Automated analysis of time transient responses in nonlinear rotor bearing systems (Year II) Computational model for tilting pad journal bearings (Year III) Linear-nonlinear force coefficients for SFDs (Year II) Making a wet (foamy) seal and estimating its dynamic forced coefficients Engineered analysis for pocket damper seals and combined labyrinth-brush seals Cost 2 $ 41, 484 4 $ 40, 984 2 $28, 470 2 $ 44, 984 2 $40, 984 18

Questions: Luis San Andres: Lsanandres@tamu. edu More information at http: //rotorlab. tamu. edu All presentations and annual report available 19

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Graduate Program in Mechanical Engineering • Enrollment --- with 387 graduate students (fall 2011; almost all full-time students); the 7 th largest and one of the most diverse mechanical engineering graduate programs in the U. S. • Faculty --- 54 T/TT faculty (http: //meen. tamu. edu/, spring 2012), including 4 endowed chair professors, 20 professors, 11 associate professors*, and 19 assistant professors* • Ranking --- 7 th among U. S. public institutions and 15 th overall (U. S. News & World Report, 2012) • Diversity --- 78 (20%) women; 214 (55%) Ph. D. students (with M. S. degrees), or 250 (65%) including direct Ph. D. students; students from 23 states in the United States and 18 other countries (fall 2011) 21

Project in negotiation Samsung Techwin (S Korea) (2 years) $160 k Predictive model for thrust collars in helically geared compressors. (+ experimental benchmarking at Turbo. Lab: Childs) Bull gear Expected + use in drive trains for wind turbines Thrust washers Pinion gear 22

VIRTUAL TOOL for TC rotordynamics Integration of nonlinear rotordynamics & bearing performance – reduces time for prototype development (35%) and saves costs in product development (30%) Honeywell Turbocharging Technologies Predicted shaft motion (2001 -2009) $600 k Measured shaft motion 23

Compare leakage: four seal types Hybrid Brush Seal HALO™ Seal Flow factor Φ for four seal types versus inlet/exhaust pressure ratio [Ps/Pe] for increasing gas inlet temperatures (300 °C). 24

Oil-free Microturbomachinery when green becomes white Oil-less turbocharger 25

Oil-Free Bearings for MTM PV/CV turbochargers and midsize gas turbines need gas bearings to secure compact units with improved efficiency in an oil-free environment. Applications as portable fuel cells (< 60 k. W) to midsize GTs (< 400 k. W) for distributed power, hybrid vehicles, CO 2 waste heat and compression systems. 2025 mandate on + efficiency for IC vehicle engines: Materials and oil-free bearing systems could enable 55 miles/gallon. Gas Bearings allow • weight reduction, lower number of parts • higher temperatures & no cooling • improved overall engine efficiency & system availability 26 26

Gas Bearings for MTM What are the needs? Make READY technology for industrial application by PUSHING development to • make out of the shelf item with proven results for a wide range of applications; • engineered product with well known manufacturing process; • known (verifiable) performance with proven laboratory and field experiences 27 27

Project in limbo GE O&G (Italy) (1 year) $100 k Enhanced model for prediction of leakage and force coefficients in pocket damper seals GE O&G interest in improving reliability of annular seals in subsea compressors, including operation under wet conditions. GT 2011 -4556 28

Oil-free MTM at TAMU • Best known program in the USA. • Licensed engineering predictive tools for gas bearings and seals and ready integration in MTM packages – high efficiency • Validation of performance – static and dynamic – on dedicated high speed test rigs. Cooperation with NASA GRC, KIST, Capstone Software Licenses BEST PAPER AWARDS 2011 IJTC J. Tribology (with KIST) 2008 IGTI S&D - Rotordynamics 2005 IGTI S&D - Rotordynamics 2003 IGTI S&D - Rotordynamics Honeywell, Borg-Warner, Becker-Turbo, Capstone MT, Barber-Nichols, NASA, SNECMA, Dresser-Rand, SWRI, R&D Dynamics, 29 KIST, Bosch

The future in the works 30