An Oil-Free Thrust Foil Bearing Facility Design, Calibration, and Operation

New testing capabilities are needed in order to foster thrust foil air bearing technology development and aid its transition into future Oil-Free gas turbines. This paper describes a new test apparatus capable of testing thrust foil air bearings up to 100 mm in diameter at speeds to 80,000 rpm and temperatures to 650 C (1200 F). Measured parameters include bearing torque, load capacity, and bearing temperatures. This data will be used for design performance evaluations and for validation of foil bearing models. Preliminary test results demonstrate that the rig is capable of testing thrust foil air bearings under a wide range of conditions which are anticipated in future Oil-Free gas turbines. Torque as a function of speed and temperature corroborates results expected from rudimentary performance models. A number of bearings were intentionally failed with no resultant damage whatsoever to the test rig. Several test conditions (specific speeds and loads) revealed undesirable axial shaft vibrations which have been attributed to the magnetic bearing control system and are under study. Based upon these preliminary results, this test rig will be a valuable tool for thrust foil bearing research, parametric studies and technology development.