Additively Manufactured Compliant Hybrid Gas Thrust Bearing for Supercritical Carbon Dioxide Turbomachinery: Experimental Evaluation and Fluid–Structure Model Predictions

Abstract

Abstract This paper presents rotating test results and advances an analytical predictive fluid–structure model for a new type of gas-lubricated thrust bearing fabricated using direct metal laser melting. The bearing concept in this study is a compliant hybrid gas thrust bearing that uses external pressurization to increase load carrying capacity, where the testing campaign in this study was only focused on steady-state static performance. The need for the bearing concept comes from enabling highly efficient supercritical carbon dioxide (sCO2) turbomachinery by replacing oil-lubricated bearings with process gas lubrication. Leveraging the process gas of the turbomachine for bearing lubrication results in lowered bearing power loss, simplified mechanical design, and allows for novel oil-free hermetic drivetrains resulting in an efficient emission-free system. The new concept utilizes hydrostatic pressurization on individual tilting pads flexibly mounted with hermetic squeeze film dampers (HSFDs). This paper focuses on rotating tests of a 173 mm outer diameter gas thrust bearing in air up to 10 krpm and hydrostatic inlet pressures to 365 psi (2.52 MPa). The influence of thrust runner speed and bearing inlet pressure on force deflection characteristics and load carrying capability of the gas film were experimentally evaluated. This work also advances a predictive fluid–structure thrust bearing model using an isothermal ideal-gas-based compressible Reynolds flow equation directly coupled to a lumped stiffness element possessing axial and rotational degrees-of-freedom. The rotating testing demonstrated load capability of 1816 lbs (8.1 kN), which equates to a thrust bearing unit load of 67 psi (0.46 MPa). Gas film force–deflection curves reveal a nonlinear relationship between thrust load and film clearance. Comparison of film thickness values with the predictive model show good agreement under high load and inlet pressure, however deviate as load and pressure decrease. Load capability was shown to increase with increasing hydrostatic inlet pressure, while the increase in thrust runner speed revealed a small decrease in load capacity.