REFLECTOR: Insulation?

Sun Jun 22 18:44:11 CDT 2008

I would like to add my evaluation of the problem and a fix that has worked for Sam DaSilva and myself for many years.  I have attached a photo to assist in you understanding the picture.

1 - The heat shield is 0.040 stainless steel a little wider than the gear leg and higher than the brake rotor. Since SS is not a very good heat conductor it is standing on top of the axle mounting block and attached to the gear with two # 8 SS sheet metal screws spaced out with two small SS washers on each screw to allow a small slot for cooling air between the gear leg and the plate.  The top of the plate is also spaced out with SS washers and is fixed with the 1/4" SS bolt that goes thru the gear leg and the leg reinforcing plate. Small dabs of silicone glue keep the plate from vibrating.

2 - The gear leg reinforcing plate is 1/4" 6061-T6 shaped to the gear leg bend and bedded in micro-glass.  This plate provides stiffness to prevent, as much as possible, the gear leg from bending if over heated.  It also acts as a backing plate for the Axel attach bolts (put steel washers on these bolts). The plate also provides some heat sink effect for the axle bolts.

 Your mileage may vary, however shielding that can also act as a heat sink as well is better.

 Jim
 James F. Agnew
Jim_Agnew_2 at Yahoo.Com
Tampa, FL
Velocity 173 Elite Aircraft Completed & Flying 

----- Original Message ----
From: "nmflyer1 at aol.com" <nmflyer1 at aol.com>
To: reflector at tvbf.org
Sent: Sunday, June 22, 2008 6:37:46 PM
Subject: Re: REFLECTOR: Insulation?

Hey Al, 

Always enjoy reading your input. Do  you think that a layer of stainless insultape material over the Bakelite stuff would add any reasonabel level of radiation away from the leg? I figured its biggest advantage was that it would insulate the gear leg from the heat transferred to the axle pad. Now I see that it might not be as big of a deal as I thought. 

Thanks 

 Kurt 

-----Original Message-----
From: Al Gietzen <ALVentures at cox.net>
To: 'Velocity Aircraft Owners and Builders list' <reflector at tvbf.org>
Sent: Sun, 22 Jun 2008 3:48 pm
Subject: Re: REFLECTOR: Insulation?

Let me put my 'heat transfer engineer' hat on; and give you my take on the heating/protecting of the gear leg issue. (you knew I would; didn't you).  It is obviously a complex configuration with different potential paths, so this is not based on any detailed analysis. 

First of all, the large majority of heat generated by the friction goes into the rotor.  Some will be transferred to the caliper, but – the brake pad is an insulator, the contact area to the puck is not large, the fluid is a relatively poor conductor, the mass of the caliper is relatively large; etc. So the caliper will heat up, but not nearly as much as the rotor.

How does the heat get from the rotor to the gear leg? Three basic path; radiation directly across the gap, conduction through the air across the gap, and conduction from the rotor to the wheel – to the axle, to the leg.  Let’s look at these in reverse order:
Conduction from the rotor to the wheel is effective but somewhat choked by the limited area of contact where the bolts are; it then has to heat up the wheel, then transfer to the bearings, through the balls (limited contact area), to the axle and on to the gear leg.  A very torturous path – so my thinking is not much goes this way.  And if it did, the first thing we would see would be damage to the tire at the bead, because that would be the first place to get hot.  I haven’t heard of heat damage to the tires.

Conduction through the air from caliper to leg: as already pointed out, air is a very good insulator, and there is nearly an inch of intervening air.  And this air is not stagnant, it is moving – a lot in the case of RG.  Not likely a significant transfer path.

That leaves radiation.  Radiant transfer goes as T (absolute) to the fourth power, times the emissivity (yes, and don’t forget Stephan-Boltzmann and their constant).  I’d guess that if you did a hard stop at night and looked at the rotors; they’d be glowing – so probably over 1400F.  The emissivity of the rotor is relatively low on the shiny part (maybe .15) and higher on the rest (maybe .4 - .5) and the absorptivity of the leg is high.  So; based on some actual calculations, the amount of heat going into the leg opposite the rotor may be 75-100 watts.  I’d say that much heat going into a small area of the leg over the period of time for a stop, and then some more braking for turning, and maybe dragging . . is definitely significant.

So, here’s the deal, too.  Whether it becomes a problem or not is critically dependant on how hot the rotor gets; if the temp is just 200 degrees higher one time, the amount of radiation heat transfer goes up by 1.5 times.  So the biggest factor is how you use your brakes.

Supposing that the above evaluation is somewhere close to reality, then the biggest gain can be made by protecting against radiation heat transfer.  By far the best way to reduce it is to interpose a layer of shiny material (something with low emissivity). One baffle of shiny metal, particularly if it is cooled by the air, can reduce the radiant transfer many fold.  Clean SS may have an emissivity of 0.05. Similar for aluminum. The foil coated insulating wrap can also be effective.

Personally I’m not that impressed with the 1/8 of high density ‘bakelite-type’ material. It’s emissivity/absoptivity is likely relatively high, and clamped against the leg, it will transfer a significant part of what it absorps.  And it’s not the greatest conduction insulator.  No doubt it will reduce the heat transfer so that’s a good thing.  

Probably in most cases, no protection is needed – as long as you are careful about minimum use of the brakes. But doing something to limit the radiation part of the equation can surely be helpful.

OK, this got long, and I won’t even guarantee that I’ve got it rightJ.

Al
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