In this failure analysis, the bump-type foil journal bearing (BFJB) is developed with various foil materials such as spring steel EN42J, phosphor bronze, Inconel X750, and SS 316. Subsequent failure analysis of the BFJB is conducted under low-speed operating conditions to evaluate their rubbing performance using the RSM technique. The study examined rotor speed and load as variable parameters, with wear rate (WR) and surface roughness (SR) of the BFJB as output responses. Additionally, a thermal imager is used to measure the rubbing temperature of the BFJB. The results indicated that Inconel X750 demonstrated superior tribological characteristics for the BFJB. With an increase in load, the wear rate of the BFJB increased while the surface roughness decreased. Among all foil materials, Inconel X750 had the most significant impact on surface roughness. The optimal values for rotor speed (S) and load (P) to enhance BFJB performance are 500 rpm and 10 N, respectively. Under these optimal conditions, the BFJB with Inconel X750 as the foil material exhibited a wear rate of 0.0150 mg/s and a surface roughness of 2.085 μm. Moreover, the BFJB made with phosphor bronze displayed the minimum rubbing temperature.
AgrawalGL. Foil air bearings cleared to land. Mech Eng1998; 120(07): 78–80.
2.
BarnettMASilverA. Application of air bearings to high-speed turbomachinery. SAE technical paper, 1970.
3.
ManojIVSrihariPVKulkarniSS, et al. Assessment of thermal effects on the levitation speed of bump foil bearings made of low cost spring steel. Measurement2016; 92: 453–463.
4.
MassiddaLVaroneA. A numerical analysis of a high temperature solar collecting tube, using helium as an heat transfer fluid. 14th SolarPACES Conference, Las Vegas, 2007.
5.
SarrazinMLiebichR. A numerical analysis of the nonlinear dynamics of shimmed conical gas foil bearings. Appl Sci2023; 13(10): 5859.
6.
ZhangCAoHJiangH, et al. Investigations on start-up performances of novel hybrid metal rubber-bump foil bearings. Tribol Int2021; 154: 106751.
7.
FengKLiuWYuR, et al. Analysis and experimental study on a novel gas foil bearing with nested compression springs. Tribol Int2017; 107: 65–76.
8.
GuanHWeiKMaoW, et al. Study on the static and dynamic performance of active bump-metal mesh foil bearings. Mech Syst Signal Process2023; 184: 109690.
9.
KimTHSan AndrésL. Heavily loaded gas foil bearings: a model anchored to test data. J Eng Gas Turbine Power2008; 130(1): 012504. DOI: 10.1115/1.2770494
10.
HouYXiongLYWangJ, et al. The experimental study of aerodynamic plate-foil journal bearings for high speed cryogenic turboexpander. Tribol Trans2000; 43(4): 681–684.
11.
CableTASan AndrésL. On the design, manufacture, and premature failure of a metal mesh foil thrust bearing—how concepts that work on paper, actually do not. J Eng Gas Turbine Power2018; 140(12): 121007.
12.
DellaCorteCRadilKCBrucknerRJ, et al. Design, fabrication, and performance of open source generation I and II compliant hydrodynamic gas foil bearings. Tribol Trans2008; 51(3): 254–264.
13.
DuanWSunYDingC, et al. Structural stiffness of X-750 alloy bump foil strips for compliant foil bearings with different heat treatments. J Tribol2016; 138(3): 031702.
14.
LaskowskiJADellaCorteC. Friction and wear characteristics of candidate foil bearing materials from 25 C to 800 C. Washington, DC: National Aeronautics and Space Administration, 1996.
15.
DellacorteCWoodJC. High temperature solid lubricant materials for heavy duty and advanced heat engines. In: 1994 fall technical conference, 1 September 1994, No. DOE/NASA/50306-5. New York: ASME.
MoczulakBŻywicaGMiąskowskiW, et al. Experimental study of the thermal and wear characteristics of a foil bearing lubricated with a low-boiling liquid. Appl Sci2023; 13(11): 6766.
WaltonJHeshmatH. Compliant foil bearings for use in cryogenic turbopumps. Proc Adv Earth-To-Orbit Propulsion Technol Conf In: NASA CP–3282, 1994, vol.1, pp.372–381.
20.
ElrodDHibbsRScharrerJ, et al. Advanced analysis of bending foil bearings for cryogenic applications. AIAA Aerospace Research Center. In: 33rd joint propulsion conference and exhibit, 1997, p.3100. DOI: 10.2514/6.1997-3100.
21.
BouchehitBBou-SaïdBGarciaM. Static and dynamic performances of refrigerant-lubricated foil bearings. IOP Conf Ser Mater Sci Eng2016; 147(1): 012043.
22.
OlszewskiAWodtkeMHryniewiczP. Experimental investigation of prototype water-lubricated compliant foil bearings. Key Eng Mater2011; 490(490): 97–105.
23.
ZhangYXiaoS. A simplified model for numerical investigation of bump-type foil bearings based on contact nonlinearity. J Tribol2022; 144(12): 121001.
24.
SadriHSchlumsHSinapiusM. Investigation of structural conformity in a three-pad adaptive air foil bearing with regard to active control of radial clearance. J Tribol2019; 141(8): 081701.
25.
ZhaoZFengKZhaoX, et al. Identification of dynamic characteristics of hybrid bump-metal mesh foil bearings. J Tribol2018; 140(5): 051702.
26.
ShalashKSchiffmannJ. Experimental assessment of a 3D-printed stainless steel gas foil bearing. J Tribol2020; 142(8): 081802.
27.
LaTrayNKimD. Novel thrust foil bearing with pocket grooves for enhanced static performance. J Tribol2021; 143(11): 111803.
28.
CarpinoMTalmageG. A fully coupled finite element formulation for elastically supported foil journal bearings. Tribol Trans2003; 46(4): 560–565.
29.
LeeYBJoJHParkDJ, et al. Dynamic characteristics of bump foils considering with thermal effect in air foil bearings. In: International joint tribology conference, 1 January 2006, Vol. 42592, pp.1327−1335. DOI: 10.1115/IJTC2006-12189.
30.
MouryaVP. BhoreS. Investigation and optimization for performance characteristics of bump-type foil journal bearings with various foil materials. Tribol Ind2022; 44(4): 664–686.
31.
ZhaoXZhangY. Analysis of the tribological and dynamic performance of textured bearings under contaminated conditions. Tribol Int2023; 187: 108732.
32.
LeeDHKimYCKimKW. The static performance analysis of foil journal bearings considering three-dimensional shape of the foil structure. J Tribol2008; 130(3): 031102. DOI: 10.1115/1.2913538
33.
MouryaVBhoreSP. Comparative study on Tribological Behavior of foil journal bearings with Micro Pocket. Surf Topogr Metrology Properties2024; 12: 015020.
34.
MouryaVBhoreSPWandalePG. Comparative investigation on wear properties of 3D-printed textured journal bearings. J Manuf Process2023; 103: 337–353.
35.
BarcelosMABarcelosMVAraújo FilhoJDS, et al. Wear resistance of AISI 304 stainless steel submitted to low temperature plasma carburizing. REM2017; 70: 293–298.
36.
ChatterjeeSHadiAS. Regression analysis by example. Hoboken, NJ: John Wiley & Sons, 2015.
