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NASA NTRS2016

Temporary Thermocouple Attachment for Thermal/Vacuum Testing at Non-Extreme Temperatures

Post-test examination and data analysis that followed a two week long vacuum test showed that numerous self-stick thermocouples became detached from the test article. The thermocouples were reattached with thermally conductive epoxy and the test was repeated to obtain the required data. Because the thermocouple detachment resulted in significant expense and rework, it was decided to investigate the temporary attachment methods used around NASA and to perform a test to assess their efficacy. The present work describes the original test and the analysis that showed that the thermocouples had become detached, temporary thermocouple attachment methods assessed in the retest and in the thermocouple attachment test, and makes a recommendation for attachment methods for future tests.

Ungar, Eugene K.↗

NASA NTRS1972

Investigation of factors affecting the heater wire method of calibrating fine wire thermocouples

An analytical investigation was made of a transient method of calibrating fine wire thermocouples. The system consisted of a 10 mil diameter standard thermocouple (Pt, Pt-13% Rh) and an 0.8 mil diameter chromel-alumel thermocouple attached to a 20 mil diameter electrically heated platinum wire. The calibration procedure consisted of electrically heating the wire to approximately 2500 F within about a seven-second period in an environment approximating atmospheric conditions at 120,000 feet. Rapid periodic readout of the standard and fine wire thermocouple signals permitted a comparison of the two temperature indications. An analysis was performed which indicated that the temperature distortion at the heater wire produced by the thermocouple junctions appears to be of negligible magnitude. Consequently, the calibration technique appears to be basically sound, although several practical changes which appear desirable are presented and discussed. Additional investigation is warranted to evaluate radiation effects and transient response characteristics.

Keshock, E. G.↗

NASA NTRS1981

Computer program for pulsed thermocouples with corrections for radiation effects

A pulsed thermocouple was used for measuring gas temperatures above the melting point of common thermocouples. This was done by allowing the thermocouple to heat until it approaches its melting point and then turning on the protective cooling gas. This method required a computer to extrapolate the thermocouple data to the higher gas temperatures. A method that includes the effect of radiation in the extrapolation is described. Computations of gas temperature are provided, along with the estimate of the final thermocouple wire temperature. Results from tests on high temperature combustor research rigs are presented.

Will, H. A.↗

NASA NTRS1992

An Automated Thermocouple Calibration System

An Automated Thermocouple Calibration System (ATCS) was developed for the unattended calibration of type K thermocouples. This system operates from room temperature to 650 C and has been used for calibration of thermocouples in an eight-zone furnace system which may employ as many as 60 thermocouples simultaneously. It is highly efficient, allowing for the calibration of large numbers of thermocouples in significantly less time than required for manual calibrations. The system consists of a personal computer, a data acquisition/control unit, and a laboratory calibration furnace. The calibration furnace is a microprocessor-controlled multipurpose temperature calibrator with an accuracy of +/- 0.7 C. The accuracy of the calibration furnace is traceable to the National Institute of Standards and Technology (NIST). The computer software is menu-based to give the user flexibility and ease of use. The user needs no programming experience to operate the systems. This system was specifically developed for use in the Microgravity Materials Science Laboratory (MMSL) at the NASA LeRC.

Bethea, Mark D.↗

NASA NTRS1993

Design of a constant tension thermocouple rake suitable for flame studies

An improved, spring-loaded thermocouple rake, suitable for studying flame structure, has been designed. This design keeps the thermocouple under tension thereby ensuring that the thermocouple does not droop due to the thermal expansion of the sensing wire when inserted in the flame. The present design allows the usage of thermocouple wire as small as 0.0508 mm and relative ease in changing thermocouple wire.

Ahuja, Sandeep↗

NASA NTRS1954

Some Effects of Exposure to Exhaust-gas Streams on Emittance and Thermoelectric Power of Bare-wire Platinum Rhodium - Platinum Thermocouples

Thermocouples were exposed to exhaust gases from the combustion of propane, 72-octane gasoline, and JP-4 fuel. Exposure increased the emissivity of the thermocouple wire, which increased its radiation error. Two methods are presented for determining the emittance of the wires. The emissivity of a clean platinum rhodium-platinum thermocouple was approximately 0.2 in the temperature range investigated, while the emittance of an exposed thermocouple coated with exhaust residue was about 0.5. The exposure caused negligible change in the thermoelectric power of the thermocouples.

Glawe, George E↗

NASA NTRS1994

High temperature, oxidation resistant noble metal-Al alloy thermocouple

A thermocouple is disclosed. The thermocouple is comprised of an electropositive leg formed of a noble metal-Al alloy and an electronegative leg electrically joined to form a thermocouple junction. The thermocouple provides for accurate and reproducible measurement of high temperatures (600 - 1300 C) in inert, oxidizing or reducing environments, gases, or vacuum. Furthermore, the thermocouple circumvents the need for expensive, strategic precious metals such as rhodium as a constituent component. Selective oxidation of rhodium is also thereby precluded.

Smialek, James L.↗

NASA NTRS2007

Cobra Probes Containing Replaceable Thermocouples

A modification of the basic design of cobra probes provides for relatively easy replacement of broken thermocouples. Cobra probes are standard tube-type pressure probes that may also contain thermocouples and that are routinely used in wind tunnels and aeronautical hardware. They are so named because in side views, they resemble a cobra poised to attack. Heretofore, there has been no easy way to replace a broken thermocouple in a cobra probe: instead, it has been necessary to break the probe apart and then rebuild it, typically at a cost between $2,000 and $4,000 (2004 prices). The modified design makes it possible to replace the thermocouple, in minimal time and at relatively low cost, by inserting new thermocouple wire in a tube.

Jones, John↗

DOE OSTI2023

Sensitivity study on the fin effect of thermocouple mounted on the heated surface under film boiling condition

In the reactivity-initiated accident (RIA) scenario, right after the power burst with the occurrence of departure from nucleate boiling (DNB), the cladding temperature quickly reaches its maximum and is maintained in a steady film boiling regime. Then, under limited heat transfer performance of film boiling, the local cooling effect by the thermocouple wire may not be neglected. A computational model is developed to estimate the local cooling effect of the thermocouple wire mounted on the cladding surface under film boiling condition. The model predicts the temperature profile along the cladding surface as physically expected and is verified against the benchmark problem. Sensitivity studies reveal the significant effects of the thickness of vapor film layer and the diameter of thermocouple on the temperature drop near the thermocouple, for they increase the heat transfer area to the liquid water region. The impact of film boiling heat transfer coefficient, however, is not significant, as the primary heat transfer mechanism near the thermocouple is the heat conduction to the wire. Future study will include the contribution of radiative heat transfer between the cladding surface and the vapor film layer, as well as a transient power history which represents an actual RIA scenario.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2023

Embedding thermocouples in SS316 with laser powder bed fusion

Recent advances in manufacturing technologies have enabled the fabrication of complex geometries for a wide range of applications, including the energy, aerospace, and civil sectors. The ability to integrate sensors at critical locations within these complex components during the manufacturing process could benefit process monitoring and control by reducing reliance on models to relate surface measurements to internal phenomena. This study investigated embedding thermocouples in a SS316 matrix using laser powder bed fusion. Under optimal processing conditions, embedded thermocouples were characterized post-building, finding good bonding to the matrix with no melt pool penetration to the sensing elements. Futher, the embedded thermocouple performed similarly to an identical non-embedded thermocouple during thermal testing to 500 °C with only a slight difference in response time, which was attributed to the differences in mass and the associated thermal time constants.

image analysis↗

NASA NTRS1970

Smoothed thermocouple tables of extended significance, volume 1

Although thermocouple calibration tables of emf (mv abs) vs temperature usually have enough significant digits for many purposes, the rounding errors often limit the use of these tables (and hence thermocouples) for precise measurements of temperature related effects such as thermal conductivity or specific heat. Fourteen calibration tables for common thermocouples from NBS Circular 561 and for cryogenic thermocouples from NBS Report 9712 were smoothed, and these are given in vol. 2 of this report. In this volume (vol.1), a general discussion of data smoothing techniques and a description of the procedures by which the smoothed tables were prepared are given.

Thermocouples↗

NASA NTRS2014

Design and Operation of a Fast, Thin-Film Thermocouple Probe on a Turbine Engine

As a demonstration of technology maturation, a thin-film temperature sensor probe was fabricated and installed on a F117 turbofan engine via a borescope access port to monitor the temperature experienced in the bleed air passage of the compressor area during an engine checkout test run. To withstand the harsh conditions experienced in this environment, the sensor probe was built from high temperature materials. The thin-film thermocouple sensing elements were deposited by physical vapor deposition using pure metal elements, thus avoiding the inconsistencies of sputter-depositing particular percentages of materials to form standardized alloys commonly found in thermocouples. The sensor probe and assembly were subjected to a strict protocol of multi-axis vibrational testing as well as elevated temperature pressure testing to be qualified for this application. The thin-film thermocouple probe demonstrated a faster response than a traditional embedded thermocouple during the engine checkout run.

thermocouples↗

NASA NTRS1972

High temperature thermocouple development program, part A and part B

The problem of extending the useful life of thermocouples intended for in-core and out-of-core thermionic applications in a vacuum environment at temperatures up to 2273 K for periods of time up to 10,000 hours was investigated. Many factors that may influence this useful life were examined, and a basic probe design was developed. With a few modifications, twenty-three thermocouple assemblies were fabricated. Generally the finished thermocouple consisted of solid doped W-3% Re and W-25% Re wires and high purity and high density BeO insulators, and was sheathed in a high purity tantalum tube. In a few probes, stranded thermocouple wires were substituted; commercial grade BeO was used; and in two cases, CVD W-22% Re tubing was used. Each of the components was made of the highest purity materials available; was subjected to special cleaning steps, and was assembled in a class 10,000 clean room. Pertinent physical and chemical properties were determined on each of the components. Special processing techniques were used in the fabrication of the high purity (99.95%), high density (over 95% of theoretical) BeO.

Toenshoff, D. A.↗

NASA NTRS1976

Studies of noble-metal thermocouple stability at high temperatures

Two investigatory studies on performance characteristics of noble-metal thermocouples are described. (1) thermoelectric stability as affected by preferential oxidation of iridium in the system iridium-40% rhodium versus iridium, and (2) the effects of temperature gradients on the emf stability of the systems platinum-13% rhodium versus platinum and iridium-40% rhodium versus iridium, operating in air. The stability investigation was carried out at three temperatures - 1700, 1850, and 2000 C - by comparing the output of the test thermocouple in air with the output of an identically constructed reference thermocouple in nitrogen. The results show that no calibration shift was observed producing a change in output greater than that corresponding to a 2.0% change in the indicated temperature for all samples tested. The investigation of gradient effects was carried out by subjecting test thermocouples to both severe and mild gradients for periods up to 200 hours. For the platinum system, the operating temperature was 1500 C with gradients of 1475 and 700 C/cm; for the iridium system, 2000 C with gradients of 700, 1500, and 1975 C/cm. Exposure to temperature gradients was found to introduce significant changes in calibration for both systems. In both investigations, the thermoelements were examined by means of electron-probe analysis and by metallographic methods to detect chemical and structural changes. Data and micrographs are presented.

Freeze, P.↗

NASA NTRS1976

Thermocouple time constant measurement by cross power spectra

A method of measuring thermocouple time constants is outlined which requires Fourier signal processing. In this method, two thermocouples of differing time constants are placed in a gas flow as closely as possible to one another, and the time constant of the first thermocouple is determined directly from the extremum of the imaginary part of the ratio of the ensemble averaged cross-power spectrum to the ensemble averaged auto-power spectrum of that thermocouple. A coherence function is given for assuring the quality of the data, and results are presented for an experimental test of the method. Some problems with the method are briefly noted.

Strahle, W. C.↗

NASA NTRS1978

Thermocouples measure very-hot gas temperatures

Thermocouple probe incorporates small jet of inert gas to cool thermocouple. To measure gas temperatures, cooling jet is turned off momentarily, allowing thermocouple to heat up to near its melting point, then cooling is reapplied. Heating curve is recorded by high speed digital system. Computing system extrapolates final temperature thermocouple would have attained.

Glawe, G. E.↗

NASA NTRS1979

Evaluation of miniature single-wire sheathed thermocouples for turbine blade temperature measurement

Chromel Alumel thermocouples were used, with sheath diameters of 0.15 and 0.25 mm. Tests were conducted at temperatures ranging from 750 to 1250 K. Both steady state and thermal cycling tests were performed for times up to 200 hours. Initial testing was performed in a low velocity gas stream for long time periods using a Meker-type burner. Additional testing was done in a high velocity gas stream for short time periods using a hot gas tunnel and also in a J75 jet engine. A total of eleven 0.15 mm diameter thermocouples and six 0.25 mm diameter thermocouples were tested. Drift rates up to 2.5% in 10 hours were observed. Photomicrographs show that this design is near the limit of miniaturization based on present manufacturing capabilities. Results indicate that the effects of miniaturization on reliability and accuracy must be considered when choosing thermocouples for a particular application.

Hollanda, R.↗

NASA NTRS1982

Adhesive-Bonded Tab Attaches Thermocouples to Titanium

Mechanical strength of titanium-alloy structures that support thermocouples is preserved by first spotwelding thermocouples to titanium tabs and then attaching tabs to titanium with a thermosetting adhesive. In contrast to spot welding, a technique previously used for thermocouples, fatigue strength of the titanium is unaffected by adhesive bonding. Technique is also gentler than soldering or attaching thermocouples with a tap screw.

Cook, C. F.↗