Search Results (18)

As interest in liquid hydrogen (LH₂) continues to grow within the energy and mobility sectors, so does the demand for testing capabilities at deep cryogenics temperatures. However, cost-, complexity-, and safety-related challenges associated with handling LH₂ effectively limit the landscape of possible options. As an alternative, LH₂ temperatures can be accessed via a helium-based cryogenic refrigerator, or “cryocooler”. Recently, NASA and its partners CB&I and Shell began the development of a cryocooler-based calorimeter to characterize the thermal performance of insulations and other materials down to 20 K. Deemed the Guarded Hot Cylinder (GHC), the apparatus utilizes a small vacuum chamber in conjunction with a GM cryocooler and trim heater to control the cold boundary temperature. A sealed, cylindrical copper cup bolts to the cryocooler and houses the material specimen, with an internal, cylindrical test heater assembly to maintain the warm boundary. The steady-state heat load, traveling radially through the specimen, is measured via the electrical input power to the test heater and then used to evaluate the material’s absolute thermal performance. Initial checkout and validation of the GHC using a common bulk-fill insulation material showed close agreement with published data from standardized LN₂ boiloff calorimetry testing. The instrument is now considered a lab standard, with the goal of incorporating it into the ASTM C1774 standard in the future, and it is in continuous use, examining insulation materials for next-generation LH₂ applications. Full article

Based on the small perturbation method, the transient pressure control equation considering real gas effects was solved, and the fitting expression for the dynamic characteristic parameters of the gas film during the start-up process was obtained. Subsequently, the influence of structural parameters of spiral-groove dry-gas seals on the dynamic tracking of the stationary ring’s motion during the non-steady-state start-up process under three-degree-of-freedom perturbations was analyzed. The results show that when the stationary and rotating rings initially separate, the stationary ring exhibits good tracking performance for both axial and angular motions of the rotating ring, although the tracking capability varies significantly. As time and film thickness increase, the tracking capability gradually weakens, and for the working film thickness, the tracking parameters tend to stabilize when the working film thickness is reached. The larger the spiral angles and the deeper the dynamic pressure grooves, the poorer the axial and angular tracking performance of the sealing ring. The number of grooves has a minimal impact on the axial and angular tracking performance of the stationary ring. A higher balance coefficient improves the axial and angular tracking performance of the stationary ring. Full article

During shearer operation, the piston rod is susceptible to wear from the invasion of pollutants, thus ruining the sealing ring in the hydraulic cylinder. This work attempts to conduct a systematic investigation of Cu-doped diamond-like carbon (Cu-DLC) film to improve the seal performance. The failure process of the cylinder was analyzed, and relevant parameters were determined. Several Cu-DLC films were deposited on the substrate of the piston rod in a multi-ion beam-assisted system, and their structures and combined tribological performances were investigated. The hardness of the film ranges from 27.6 GPa to 14.8 GPa, and the internal stress ranges from 3500 MPa to 1750 MPa. The steady-state frictional coefficient of the film ranges from 0.04 to 0.15; the wear rate decreases first and then increases, and it reaches its lowest (5.0 × 10⁻⁹ mm³/N·m) at 9.2 at.% content. a:C-Cu_9.2% film presents optimal combined tribological performances in this experiment. The modification mechanism of Cu-DLC film for the seal performance may come from the synergistic effects of (i) the contact force and friction-heat-induced film graphitization, (ii) Cu doping improves the toughness of the film and acts as a solid lubricant, and (iii) the transfer layer plays a role in self-lubrication. Full article

To obtain an optimal range of structural parameters for dry-gas seals with good performance, this study employed advanced sensing technology to monitor and analyze the internal flow characteristics of dry-gas seals in real time. Additionally, the validity of the calculation program was verified through experimentation. Using steady-state performance parameters as evaluation indices, a calculation model with lubrication characteristics was developed. The results indicate that when there are 12 grooves, the gas film pressure distribution is uniform and has a high value. At pressures greater than 2 MPa, the opening force, leakage, and gas film stiffness change significantly due to enhanced dynamic pressure effects with high-pressure differences, which reduces the local contact forces and frictional forces. At a constant speed, decreasing the gas film thickness increases the pressure difference while increasing both the opening force and film stiffness; however, at higher rotational speeds where the gas flow becomes non-uniform, the stability of the gas film is affected, leading to increased frictional forces. When there are between 10 and 16 grooves with depths ranging from 5.0 to 6.0 μm, dynamic pressure effects caused by pressure gradients become apparent, resulting in good dry-gas sealing performance being achieved. This research provides a theoretical reference for optimizing the design of dry-gas seals, as well as their steady-state seal performance. Full article

Traditional oil seals are insufficient for the high-speed and bi-directional rotation of new energy electric vehicles. Therefore, we developed a Python program focusing on micro-groove pump seals and examined the unexplored non-contact oil–air biphasic internal end-face seals. Real gas effects were described using the virial and Lucas equations. We introduced an oil–air ratio to determine the equivalent density and viscosity of the two-phase fluid in the seal. Furthermore, we solved the compressible steady-state Reynolds equation using the finite difference method. Analysing the seal’s pumping mechanisms and the effects of operating parameters on sealing performance, we assessed 17 types of hydrodynamic grooves. The results demonstrate that inverse fir tree-like grooves perform well under typical sealing conditions. Under the conditions given in this study, the pumping rate of the optimal groove type compared to other groove types even reached 633.54%. In the oil–air biphasic state, the micro-groove pump seal exerts significant dynamic pressure on the sealing surface. Seal opening force increases with rotational velocity, oil–air ratio, and inlet pressure but decreases with temperature. The pumping rate first increases and then decreases with rotational velocity, increases with oil–air ratio and temperature, and then decreases with inlet pressure. Some special working points require consideration in sealing design. Our results provide insights into designing micro-grooved pumping seals for new energy electric vehicles. Full article

A dry gas seal (DGS) is one of the key basic components of natural gas transmission pipeline compressors, and the sealing performance of a DGS dealing with complex multi-component pipeline natural gas is different from that dealing with conventional nitrogen medium. In this paper, a spiral groove DGS of the compressor in natural gas transmission pipeline systems is taken as the research object. The thermal hydrodynamic lubrication model of the DGS is established considering turbulence effect and choking effect. Based on the finite difference method, the temperature and pressure distributions and the steady-state performance of the DGS are obtained by simulating. The influence of unitary impurity compositions such as light hydrocarbon, heavy hydrocarbon, non-hydrocarbon, and their contents on the steady-state performance of the DGS is analyzed. The steady-state performance of the DGS dealing with multi-impurity natural gas such as in the West-East gas transmission is investigated under different operating conditions. The results show that turbulence had a significant effect on the DGS, while choking had a weak effect. Increasing the content of light hydrocarbon such as C₂H₆ and heavy hydrocarbon such as C₅H₁₀ resulted in an increase in the gas film stiffness, leakage rate, and the temperature difference between the inlet and outlet, while non-hydrocarbon, such as N₂, reduced the temperature difference between the inlet and outlet. The greatest impact on seal performance was produced by the heavy hydrocarbon, followed by the light hydrocarbon, and the least was produced by the non-hydrocarbon. Full article

This study presents a numerical approach to the design and optimization of centrifugal impellers used in the pumps of active thermal control systems of spacecraft. Although launch costs have shrunk in the last decade, the performance requirements, such as efficiency and reliability, have increased, as such systems are required to work up to 15 years, depending on the mission. To that effect, our paper deals with the first step in this pump design, namely the hydraulic optimization of the impeller. Constructively, this type of impeller allows for certain balancing systems and labyrinth seals to be applied in a more effective way, as well as allowing for additive manufacturing methods to be used—however, details regarding these aspects are beyond the scope of the current paper. By combining empirical formulas, computational fluid dynamics (CFD) analysis, and artificial neural networks (ANNs), the research focuses on achieving high efficiency and fast manufacturing. A series of geometries have been sized and validated using steady-state RANS (Reynolds Averaged Navier-Stokes) simulations, leading to the identification of the most efficient configuration. Subsequent optimization using an ANN resulted in a refined impeller design with notable improvements in hydraulic performance: a 3.55% increase in efficiency and a 7.9% increase in head. Key parameters influencing impeller performance, including blade number, incidence, and backsweep angles, are identified. This approach offers a comprehensive method to address the evolving requirements of space missions and contributes to the advancement of centrifugal pump technology in the space domain. Full article

Mechanical seals ensure the internal sealing of centrifugal pumps from the surrounding environment. They are one of the most critical components in a centrifugal pump. For this reason, the condition of mechanical seals should be monitored during operation. Mechanical seal friction power is an important component of mechanical losses in centrifugal pumps and is used as an indicator of wear and therefore seal condition. The soft sensor described in this paper is based on temperature measurements at the seal and can be used for determining the frictional power performance. A major factor in determining frictional power performance is the heat transfer between the mechanical seal and the medium inside the pump. For calculating the heat transfer, the stationary temperature fields in the rings of the mechanical seal are described by transmission efficiencies. The root mean squared error was determined for steady-state operating conditions to assess the quality of the soft sensor calculation. The frictional power performance can be determined by recording the temperature at the mechanical seal mating ring and the medium. The algorithm detects when the steady-state operating conditions change but does not map the dynamic changes between the stationary operating conditions. Full article

High-performance aeroengine design is an important component of modern industry, and advanced sealing technology is a key technology to meet the engine fuel consumption rate, thrust-to-weight ratio, pollutant emission, durability, and lifetime. Reducing the internal airflow leakage of the engine through a sealing technology can improve the performance and efficiency of the engine. In this paper, the typical sealing technology for an aeroengine is introduced in more detail, including the structural characteristics and use limitations of the labyrinth seal, brush seal, honeycomb seal, gas film face seal, and cylindrical gas film seal. It focuses on the development history, typical structure type, working principle, basic technology research method, steady-state performance, dynamic characteristics, multi-physical field coupling, structural deformation, experimental testing, processing technology. Finally, it summarizes the problems and future development trends of the current application of the cylindrical gas film seal in aeroengines, and points out that the seal performance test and evaluation based on advanced composite sensor technology and the innovative design of the seal based on new material, a new principle, and a new structure will be the new research direction. Full article

Underwater manipulation is one of the most significant functions of the deep-sea crawling and swimming robot (DCSR), which relies on the high-accuracy control of the body posture. As the actuator of body posture control, the position control performance of the underwater mechanical leg (UWML) thus determines the performance of the underwater manipulation. An adaptive super-twisting sliding mode control method based on the extended state observer (ASTSMC-ESO) is proposed to enhance the position control performance of the UWML by taking into account the system’s inherent nonlinear dynamics, uncertainties, and the external disturbances from hydrodynamics, dynamic seal resistance, and compensation oil viscous resistance. This newly designed controller incorporates sliding mode (SMC) feedback control with feedforward compensation of the system uncertainties estimated by the ESO, and the external disturbances of the hydrodynamics by fitting the parameters, the dynamic seal resistance, and the compensation oil viscous resistance to the tested results. Additionally, an adaptive super-twisting algorithm (AST) with integral action is introduced to eliminate the SMC’s chattering phenomenon and reduce the system’s steady-state error. The stability of the proposed controller is proved via the Lyapunov method, and the effectiveness is verified via simulation and comparative experimental studies with SMC and the adaptive fuzzy sliding mode control method (AFSMC). Full article

Designing a composite, possibly strengthened by a dispersion of (fine) oxides, is a favorable way to improve the mechanical characteristics of Cu while maintaining its advantageous electric conductivity. The aim of this study was to perform mechanical alloying of a Cu powder with a powder of Al₂O₃ oxide, seal the powder mixture into evacuated Cu tubular containers, i.e., cans, and apply gradual direct consolidation via rotary swaging at elevated temperatures, as well as at room temperature (final passes) to find the most convenient way to produce the designed Al₂O₃ particle-strengthened Cu composite. The composites swaged with the total swaging degree of 1.83 to consolidated rods with a diameter of 10 mm were subjected to measurements of electroconductivity, investigations of mechanical behavior via compression testing, and detailed microstructure observations. The results revealed that the applied swaging degree was sufficient to fully consolidate the canned powders, even at moderate and ambient temperatures. In other words, the final structures, featuring ultra-fine grains, did not exhibit voids or remnants of unconsolidated powder particles. The swaged composites featured favorable plasticity regardless of the selected processing route. The flow stress curves exhibited the establishment of steady states with increasing strain, regardless of the applied strain rate. The electroconductivity of the composite swaged at elevated temperatures, featuring homogeneous distribution of strengthening oxide particles and the average grain size of 1.8 µm², reaching 80% IACS (International Annealed Copper Standard). Full article

High dynamic performance of a deep-sea electric oil-filled joint actuator is an important premise to guarantee the working performance of an electric underwater manipulator. However, the unfavorable factors (i.e., extremely high water pressure, near freezing temperature) brought by the deep-sea working environment seriously affect the characteristic and dynamic performance of the electric oil-filled joint actuator, which mainly includes oil stirring viscos loss, output shaft dynamic seal loss, and core loss. In this paper, a novel observer-based robust control method named prescribed performance non-singular fast-terminal sliding-mode control (PP-NFTSMC-ESO) was synthesized for improving the dynamic performance of a deep-sea electric oil-filled joint actuator. The extended state observer (ESO) was employed to observe the unmeasured joint velocity signal and estimate the lumped uncertainties, while the prescribed performance function (PPF) was applied to constrain the instantaneous and steady-state performance of the trajectory-tracking error. The robust NFTSMC control method was then established by integrating the function of ESO and PPF through backstepping methodology. The stability of the proposed PP-NFTSMC-ESO strategy was analyzed and proved by the Lyapunov’s stability theory. It was proven that under the proposed controller, all the closed-loop signals are bounded and the trajectory tracking errors will converge to a small neighborhood of the origin with appropriate design parameters. The effectiveness of the proposed control scheme was illustrated by comparative simulation studies. Full article

This study aims to accurately simulate the outfield low-temperature environment for the key components of aircraft in the parking state, using the infield low-temperature environmental test chamber, when there is a difference between the infield and outfield environments; and, moreover, reveal the similarity between the influences of the infield and outfield low-temperature environments on the elastic properties of the rubber sealing materials for aircraft. Two kinds of rubber materials were examined in the infield and outfield—the tensile springback test and the isobaric elongation test—and the measured data of low-temperature steady-state response (elastic property) were obtained under the typical temperature of −40 to 10 °C, finding that there is difference of elastic property between the infield and outfield environment. Three fitting methods were then used to describe the relationship between elasticity and temperature. In view of the difference of the elastic response of the typical rubber sealing materials to the low-temperature infield and outfield, a similarity calculation method of infield and outfield low-temperature tests was proposed, based on the translation and scaling transformation of the similarity curve. The outfield test data verify that the method proposed has high goodness of fit, and it is feasible and generalizable in the low-temperature performance testing and research of rubber materials and components. Full article

Hydraulic dynamic seals for reciprocating or alternating motion are machine elements with widespread applications in the automotive, aerospace, marine, pharmaceutical and several other industrial sectors. They have been under commercial development for many decades, and are often met in critical positions, consuming a considerable amount of energy during operation. An objective function of mass leakage rate, friction force and an abrasive-wear representative term is proposed in the present study to evaluate the performance of hydraulic, polymeric sliding seals under suitable constraints. Using Variational Calculus, analytical and numerical techniques, the objective function is minimized, resulting in an optimal seal profile that maximizes sealing performance for given, steady-state operating conditions, in additional consideration of the structural integrity and manufacturability of the modified seal. The obtained seal shape and related pressure distribution are reminiscent of those for U-cup and step seals, designs that dominate the industry. In the course of the mathematical analysis, some major obstacles are documented that show how sensitive and complicated sealing performance really is. Full article

The steady-state injection characteristic of gas fuel injector is one of the key factors that affects the performance of gas fuel engine. The influences of different injection strategies, such as different injection angles and different injection positions, on the mixing performance in gas-fueled engine have been emphasized in previous literatures. However, the research on the injection characteristics of the gas fuel injector itself are insufficient. The three-dimensional steady-state computational fluid dynamics (CFD) models of two kinds of injectors, in different opening manners, and the other two kinds of injectors, in different sealing methods, were established in this paper. The core region speed, stagnation pressure loss and mass flow rate were compared. Additionally, the effective injection pressure (EIP) concept was also used to evaluate the injection efficiency of gas fuel injector. The simulation results show that the jet speed of the pull-open injector is higher than the push-open injector under the same operating conditions. The injection efficiency of the pull-open valve is about 56.0%, while the push-open valve is 50.3%. In general, the steady-flow characteristic of the pull-open injector is better than that of the push-open one. The injection efficiency of the flat sealing injector is 55.2%, slightly lower than the conical sealing method. Full article