The Effect of Journal Roughness and Foil Coatings on the Performance of Heavily Loaded Foil Air Bearings

Abstract

Foil air bearing load capacity tests were conducted to investigate if a solid lubricant coating applied to the surface of the bearing's top foil can function as a break-in coating. Two foil coating materials, a conventional soft polymer film (polyimide) and a hard ceramic (alumina), were independently evaluated against as-ground and worn (run-in) journals coated with NASA PS304, a high-temperature solid lubricant composite coating. The foil coatings were evaluated at journal rotational speeds of 30,000 rpm and at 25 °C. Tests were also performed on a foil bearing with a bare (uncoated) nickel-based superalloy top foil to establish a baseline for comparison. The test results indicate that the presence of a top foil solid lubricant coating is effective at increasing the load capacity performance of the foil bearing. Compared to the uncoated baseline, the addition of the soft polymer coating on the top foil increased the bearing load coefficient by 120 percent when operating against an as-ground journal surface and 85% against a run-in journal surface. The alumina coating increased the load coefficient by 40 percent against the as-ground journal but did not have any effect when the bearing was operated with the run-in journal. The results suggest that the addition of solid lubricant films provide added lubrication when the air film is marginal, indicating that as the load capacity is approached foil air bearings transition from hydrodynamic to mixed and boundary lubrication.