Tribology Group Rotordynamics Laboratory May 2012 32nd 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

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

Students Tribology Group Top: Feng Yu Owen Zhang Jose Hernandez Sung-Hwa Jeung Gary Bradley Bottom Yujiao Tao Alain Anderson Joshua Norsworthy Stephanie Simerskey Qing Liu

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

Modeling thrust foil bearings for PV & CV Turbos 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 (0-5W) and higher inlet temperatures (~150C). 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)

2010-12 TRC funding Project progress status follows Measurement of leakage in a novel all metal non-contacting annular seal at high temperature TRC (10-12) $ 74.8k (2 years) HALO™ Seal Labyrinth seal High temperature seal test rig (300 C=572 F) HALOTM seal Project progress status follows

2010-12 TRC funding Computational model for tilting pad journal bearings TRC (10-12) $ 70.4k (2 years) For high load bearings (> 150 psi), improve correlation to experimental force coefficients by adding pad-pivot flexibility and fluid energy transport & thermal effects ASME GT2008-50069 Carter & Childs, Technical presentation follows Test TAMU TPB (Wilkes) New Model YY New Model XX XX YY Test Test rotor speed 13.1 krpm

2011-12 TRC funding Technical presentation follows Automated Analysis of XLTRC2 Time Transient Responses in Nonlinear Rotor Bearing Systems TRC (11-12) $ 34.8k (1 year) Manage output of XLTRC2 time response of NL rotor-bearing motions & characterize frequency and modal content Technical presentation follows

2011-12 TRC funding: Gas bearings for MTM Metal Mesh Foil Bearings: Operation at High Temperature TRC (11-12) $ 36.6k (1 year) State of the art predictive tools benchmarked to test data Technical presentation follows. Report TRC-BC001-12 Oil free TM research past funding TRC (2003-2009) $ 312 k NSF (2003-2006) $ 255.5k NASA GRC (2007-2009) $ 284.6k Capstone (2007) $ 64.7 k

Shaker assembly (Y direction) Shaker assembly (X direction) 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) $ 436k TRC (12) $ 39.k (1 year) Static loader Shaker assembly (Y direction) Shaker assembly (X direction) SFD test bearing Technical presentation follows Report TRC-SFD-01-12

Non-contacting gas face seal with textured pattern Other industrial project Computational analysis of textured gas face seals for steam turbines CIATEQ A.C. (Mexico) (2010-12) Sponsors1 grad student Replace carbon rings to increase turbine reliability. Model novel textured face seal geometries and GUI for whole seal cartridge Non-contacting gas face seal with textured pattern Typical steam turbine for lubrication system mechanical drive

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, CONACYT-Mexico, Brazil Education Ministry.

The rankings 2012: 15th among all institutions

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 Diversity students 2012 2 PhD (1F) 6 MS (1F, 1H) 2 UGS (1F, 2AM) Graduating 08/2012 PhD Thomas Chirathadam (SwRI) MS Yujiao Tao MS Jose Hernandez (CIATEQ, Mx) MS Feng Yu Do more with nothing!

Performance Funding 2010-2012 $ 208.3k (Honeywell) + 97.2k (Pratt & Whitney) + 90.4k (Borg Warner) + 146.2k (TRC-2011) 542.1k + $ 68.0k software licenses Research expenditures $ 246.4k (FY 11) $ 182.2k (FY 12)

Scholarship 08 09 10 11 12 Total 2011-2012 Journal (peer reviewed) 5 6 2 8 Conference (peer reviewed) 7 Conference (NOT peer reviewed) Book Chapters 1 3 Accepted/awaiting publication 4 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 GT2011-45274. 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

2012 TRC reports TRC-SFD-01-12 TRC-BC001-12 Force Coefficients for a Large Clearance Open Ends SFD with a Central Feed Groove: Test Results and Predictions TRC-BC001-12 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 XLTRC2 modeling (Q.Liu)

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

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

Graduate Program in Mechanical Engineering Enrollment --- with 387 graduate students (fall 2011; almost all full-time students); the 7th 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 --- 7th among U.S. public institutions and 15th 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)

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

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 (2001-2009) $600k Predicted shaft motion Measured shaft motion

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

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

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 kW) to midsize GTs (< 400 kW) for distributed power, hybrid vehicles, CO2 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

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

Project in limbo GE O&G (Italy) (1 year) $100 k Enhanced model for prediction of leakage and force coefficients in pocket damper seals GT2011-4556 GE O&G interest in improving reliability of annular seals in subsea compressors, including operation under wet conditions.

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, KIST, Bosch

The future in the works