On the Design, Manufacture, and Premature Failure of a Metal Mesh Foil Thrust Bearing—How Concepts That Work on Paper, Actually Do Not

Abstract

Oil-free microturbomachinery (OFT) implements compliant foil bearings because of their minute drag and ability to operate in extreme (high or low) temperature. Prominent to date, bump-foil thrust bearings integrate an underspring thin metal structure that provides resilience and material damping, and while the rotor is airborne, it acts in series with the stiffness and damping of the gas film. The design and manufacturing of foil bearings remain costly as it demands extensive engineering and actual experience. Alternative foil bearing configurations, less costly and easier to manufacture, are highly desirable to enable widespread usage of OFT. This paper details the design and manufacturing of a novel Rayleigh-step metal mesh foil thrust bearing (MMFTB) as well as its testing on a dedicated rig. Metal mesh structures offer significant material structural damping and can be easily procured at a fraction of the cost of a typical bump-foil strip layer. The MMFTB consists of a solid carrier, a number of stacked annular copper mesh sheets (wire diameter = 0.25, 0.3, and 0.41 mm), and a steel top foil (0.127 mm thick) that makes six pads (ID = 50.8 mm, OD =2 ID), each 45 deg in extent. A 3 μm polymer coats each pad, and a photochemical process etches a step 20 μm in height. Static and dynamic load measurements (without rotor speed) demonstrate that the MMFTB has structural stiffness and material damping similar to that of a publicized bump-type foil thrust bearing. A maiden test of the MMFTB with rotor speed of Ω = 15 krpm (∼80 m/s at bearing outer diameter (OD)) proved briefly the bearing operation when applying a tiny thrust load. Further tests with ambient air, a rotor speed of 40 krpm (∼212 m/s at bearing OD), and a very light load/area <7 kPa failed several of the prototype bearings, all exhibiting significant wear on one or more pads. The source of the failure is the inherent unevenness of the metal mesh stacked substructures, thus causing the pads to bulge toward the rotor collar surface before a load applies. A deficient anchoring method exacerbates the unevenness. Incidentally, a high rotor speed induced large windage that lifted the top foils pushing them against the spinning collar. As the bearing moved toward the rotating collar to begin applying thrust, the local high spots rubbed against the collar before a hydrodynamic wedge could form to separate the surfaces. Without a robust sacrificial coating, metal-to-metal contact quickly disfigured the contacting top foil pads, erasing the etched step, and leading to failure. In concept, and on paper, the mesh sheets and the top foil lay flat against the bearing carrier, giving a false sense of uniformity in the design process. In actuality, a designer must consider the manufactured states of the individual components and how they assemble. A redesign of the bearing intends to overcome the existing flaws (highlighted herein) by incorporating a thicker top foil that is well anchored (to better withstand the effects of windage), a robust sacrificial coating, and a hydrodynamic wedge accomplished via a circumferential taper on each pad.

Investigation and Optimization for Performance Characteristics of Bump-type Foil Journal Bearings with Various Foil Materials

“…The author considered the stainless steel material for the foil strip. Cable and Andres [22] developed the metal mesh foil thrust bearings by considering Stainless Steel 316 for the bearing and copper for the mesh substructure. However, some researchers used other materials such as beryllium copper to develop and analyze the foil bearings [23,24].…”

Numerical investigation of slip flow phenomenon on performance characteristics of gas foil journal bearing

“…Lee et al carried out a numerical and experimental investigation to assess the static and dynamic characteristics of the GFB by integrating the bending effect of top foil and the interaction between bump foil and top foil [13]. Owing to the substantial reliance of dynamic properties on the design and elastic properties of the bump foil [14], different configurations of foil, other than the conventional corrugated bump foil, have been proposed in the state-ofthe-art to meliorate the load-carrying capacity and stability of GFBs [15][16][17][18]. In Tkacz et al numerically analyzed the dynamics of a GFJB, considering the relative motion and friction between the stationary elements of the sleeve [19].…”