Research Progress on Materials, Structures, and Lubrication Performance of Thrust Bearings in Large Hydro-turbine Units

YANG Ziyi; TANG Zhengyang; XUE Bing; LI Yongbo; LI Hu; XIANG Aijun; WANG Youqiang

doi:10.16490/j.cnki.issn.1001-3660.2025.20.003

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Surface Technology ›› 2025, Vol. 54 ›› Issue (20) : 28-43. DOI: 10.16490/j.cnki.issn.1001-3660.2025.20.003

Research Review

Research Progress on Materials, Structures, and Lubrication Performance of Thrust Bearings in Large Hydro-turbine Units

YANG Ziyi^1a, TANG Zhengyang^2,3, XUE Bing^2,3, LI Yongbo^2,3, LI Hu², XIANG Aijun^2,3, WANG Youqiang^1a,1b,*

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Abstract

The global transition towards green and low-carbon energy systems has elevated hydropower as a critical clean energy source, placing significant emphasis on the reliability and efficiency of hydro-turbines. As the key component bearing the entire axial load (including rotor weight and hydraulic thrust) in vertical hydro-turbine units, the lubrication performance of thrust bearings directly dictates operational stability and longevity. The work aims to provide a comprehensive review of the research progress on thrust bearings and their lubrication characteristics in large hydro-turbine units, focusing on structural design, material selection, and lubrication analysis methodologies.
The structural characteristics of thrust bearings are systematically examined, focusing on six primary support designs and their operational suitability. Rigid pillar bolt supports, though simple, require extreme manufacturing precision and lack adaptability, making them unsuitable for high-load applications. Spring cluster supports excel in load distribution and thermal performance but demand high-precision manufacturing. Elastic oil tank systems offer superior self-balancing through interconnected pressurized oil chambers, yet their complexity and potential leakage risk limit widespread adoption. Elastic rubber pad supports provide cost-effective solutions for low-load scenarios with inherent insulation benefits, but their limited load capacity and fatigue susceptibility restrict heavy-duty use. Elastic disc supports feature compact designs with uniform load distribution, though their spherical contact surfaces may induce stress concentrations. The most advanced solution—elastic pin cluster-supported double-layer pads—effectively mitigates thermal and mechanical deformation through optimized pin arrangements, enabling precise load balancing and reducing maintenance costs. Additionally, the critical role of hydrostatic lifting systems is analyzed, emphasizing how injection pocket geometry (circular, trapezoidal, rectangular) affects pressure distribution and thermal performance. Shallow pockets enhance lubrication by maintaining pressure fields, whereas deep pockets reduce effective load-bearing area, underscoring the need for design optimization to balance lift capacity and hydrodynamic efficiency.
Furthermore, the analytical methods for studying lubrication characteristics are elaborated. The Thermo-Hydrodynamic (THD) and Thermo-Elasto-Hydrodynamic (TEHD) lubrication analyses are detailed based on the Reynolds equation, which incorporates the viscosity-temperature effects and the coupled thermal-elastic deformation of pads and runner plates. While traditionally relying on simplified 2D models, advancements now emphasize the necessity of 3D TEHD analysis coupled with realistic 3D structural models for higher accuracy. The limitations of Reynolds-based methods (neglecting inertia, complex geometry simplifications, assumed boundary conditions) are highlighted. Consequently, Computational Fluid Dynamics (CFD) has emerged as a powerful tool for precise TEHD analysis. CFD enables full 3D modeling of the fluid domain, including complex features like pockets and grooves, and facilitates robust fluid-structure-thermal interaction (FSTI) simulations without a priori assumptions about heat transfer coefficients. Studies utilizing CFD, including comparisons with experimental data, validate its effectiveness in capturing the complex lubrication phenomena in large thrust bearings.
Finally, the review concludes by emphasizing four key research priorities: optimization of support structure designs, development of innovative composite materials, and deeper investigation of multi-scale lubrication mechanisms, and advancement of intelligent monitoring and maintenance of lubrication systems. Future studies should particularly focus on enhancing bearing stability under extreme operating conditions, improving material performance characteristics, refining analytical techniques to better understand transient behaviors during start-up, shutdown, and dynamic operational phases, and implementing smart operation and maintenance strategies for lubrication systems.

Key words

large hydro-turbine units / thrust bearings / support structures / hydrostatic lifting device / bearing materials / lubrication performance analysis

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YANG Ziyi, TANG Zhengyang, XUE Bing, LI Yongbo, LI Hu, XIANG Aijun, WANG Youqiang. Research Progress on Materials, Structures, and Lubrication Performance of Thrust Bearings in Large Hydro-turbine Units[J]. Surface Technology. 2025, 54(20): 28-43 https://doi.org/10.16490/j.cnki.issn.1001-3660.2025.20.003

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