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Thermocouple continuously measures a flowing gas up to 4500 degrees F in a hazardous environment. The thermocouple combines rhenium and tungsten in the probe, housing, and swaged extension lead. The wires extend continuously from the cold junction to the probe tip to eliminate errors from secondary thermocouple effects.
Flight reentry experiments define the total heating on a large blunt-nosed body by means of imbedded thermocouples. The thermocouples, installed in a beryllium layered forebody, were designed to provide minimum feasible disturbance of local heat flow with accurate depth control of the thermocouple junction locations.
Tungsten-rhenium alloy thermocouples, specifically, insulated, sheathed W/W plus 26Re and W plus 5 Re/W plus 26 Re thermocouples, are effective for temperature measurement in excess of 2920 degrees C. These thermocouples have a high thermoelectric output and excellent relationship to temperatures up to 2760 degrees C.
New furnace calibrates unknown thermocouple by comparing its electrical output to a reference thermocouple /previously calibrated by optical pyrometry/, as both are heated simultaneously. Thermocouples may be radioactive, thus heat source must be accessible by remote manipulation and inspection measurements. Advantages of furnace operation are cited.
Three performance characteristics of noble metal thermocouples in various environments are discussed. Catalytic effects cause significant errors when noble metal thermocouple materials are exposed to air containing unburned gases in temperature ranges from 25 C to 1500 C. The thermoelectric stability of the iridium 40 rhodium to iridium thermocouple system at 2000 C in an oxidizing medium is described. The effects of large and small temperature gradients on the accuracy and stability of temperature measurements are analyzed.
The effect of exposure of bare-wire and BeO-insulated commercial W-Re thermocouple materials to high temperatures in gaseous environments was investigated. The temperature range of interest was primarily 2000 to 2400 K, and the investigations were confined to thermocouple wires of 0.25 mm diameter. Thermoelements were examined for metallurgical structural changes and chemical changes by conventional methods. In the temperature range of interest, grain growth was inhibited in the chemically doped W-3% Re alloy, and excellent room-temperature ductility was retained subsequent to the exposure. The compatibility of high purity (in excess of 99.8%), sintered BeO insulators with the thermoelements differed, depending upon whether the BeO-insulated thermoelement assemblies were self-heated electrically or heated in a furnace; in tests in argon environments, highly reliable performance occurred when the assemblies were heated in a furnace. BeO-insulated W-3% Re vs W-25% Re thermocouples, constructed with degassed and aged materials, exhibited drifts equivalent to about 3 mK/hr during 1000 hours of exposure at 2073 K in argon while in the presence of tantalum.
A theory has been developed to describe the performance of thermocouples which have been formed by electroplating portions of one thermoelectric material with another. The electroplated leg of the thermocouple was modeled as a collection of infinitesimally small homogeneous thermocouples connected in series. Experiments were performed using several combinations of Constantan wire sizes and copper plating thicknesses. A transient method was used to develop the thermoelectric calibrations, and the theory was found to be in quite good agreement with the experiments. In addition, data gathered in a Soviet experiment were also found to be in close agreement with the theory.
A technique for fabricating Chromel and Alumel thin film thermocouples was developed. Turbine blade metal temperatures measured with the thin film thermocouple installation were compared with those of a reference sheathed (wire) thermocouple. Good agreement was obtained, and the results are encouraging.
Ascent heating data were obtained at conditions simulating real gas effects at hypersonic Mach numbers. The configurations tested were Orbiter alone, external tank alone, and mated Orbiter and external tank. A boundary layer trip investigation was conducted for all configurations. The test was conducted at Mach 6 and Reynolds number of one half million per foot for 0 deg and -5 deg angle-of-attack. Selected thermocouples were chosen from the Orbiter and external tank to be used for obtaining heat transfer measurements. A maximum of 42 thermocouples could be measured by the facility data acquisition at one time and no attempt was made to record the excess thermocouples located on the model. Photographs of the test configurations are shown.
A thermocouple assembly which includes a plug having a pair of small diameter holes near one end thereof which are spaced a small distance apart to leave a thin quantity of plug material between the holes is presented. There are a pair of thermocouple wires extending through the different holes and with the outer ends of the wires joined to the thin quantity of plug material which lies between the holes to form a thermocouple junction.
Thin platinum film on thermocouple sheath protects non-noble-metal thermocouples from deterioration in oxygen-rich atmosphere. Coating works on nickel-alloy sheathed thermocouples otherwise destroyed by corrosion in pure oxygen at 1,000 degrees C.
Metal particles in adhesive aid heat transfer. Aluminum caps containing silver-filled epoxy used as high-thermal-conductance anchors for thermocouples, epoxy providing thermal path between mounting surfaces and thermocouple measuring junctions. Normally, epoxy-filled aluminum caps used when measuring steady-state temperatures. Silver-filled epoxy used when thermocouple not isolated electrically from surface measured.
A semiconductor thermocouple unit is provided for heating and cooling memory metal actuators. The semiconductor thermocouple unit is mounted adjacent to a memory metal actuator and has a heat sink attached to it. A flexible thermally conductive element extends between the semiconductor thermocouple and the actuator and serves as a heat transfer medium during heating and cooling operations.
Theoretical expressions are derived for the steady-state frequency response of a thermocouple wire. In particular, the effects of axial heat conduction are demonstrated for both a uniform thermocouple wire and a nonuniform wire with unequal material properties and wire diameters across the junction. For the case of a uniform wire, the amplitude ratio and phase angle compare favorably with the series solution of Scadron and Warshawsky (1952) except near the ends of the wire. For the case of a non-uniform wire, the amplitude ratio at low frequency omega yields 0 agrees with the results of Scadron and Warshawsky for a steady-state temperature distribution. Moreover, the frequency response for a non-uniform wire in the limit of infinite length l yields infinity is shown to reduce to a simple expression that is analogous to the classic first order solution for a thermocouple wire with uniform properties.
Thermocouple-signal-conditioning circuit acting in conjunction with thermocouple, exhibits electrical behavior of voltage in series with resistance. Combination part of input bridge circuit of controller. Circuit configured for either of two specific applications by selection of alternative resistances and supply voltages. Includes alarm circuit detecting open circuit in thermocouple and provides off-scale output to signal malfunctions.
Theoretical expressions are derived for the steady-state frequency response of a supported thermocouple wire. In particular, the effects of axial heat conduction are demonstrated for both a supported one material wire and a two material wire with unequal material properties across the junction. For the case of a one material supported wire, an exact solution is derived which compares favorably with an approximate expression that only matches temperatures at the support junction. Moreover, for the case of a two material supported wire, an analytical expression is derived that closely correlates numerical results. Experimental data were taken with a type K supported thermocouple. The test thermocouple was constructed with dimensions to demonstrate the effects of axial heat conduction assuming constant physical properties across the junction.
A fine-wire thermocouple probe was used to determine freestream stagnation temperatures in hypersonic flows. Data were gathered in a N2 blowdown wind tunnel with runtimes of 1-5 s. Tests were made at supply pressures between 30 and 1400 atm and supply temperatures between 700 and 1900 K, with Mach numbers of 14 to 16. An iterative procedure requiring thermocouple data, pilot pressure measurements, and supply conditions was used to determine test cell stagnation temperatures. Probe conduction and radiation losses, as well as real gas behavior of N2, were accounted for during analysis. Temperature measurement error was found to be 5 to 10 percent. A correlation was drawn between thermocouple diameter Reynolds number and temperature recovery ratio. Transient probe behavior was studied and was found to be adequate in temperature gradients up to 1000 K/s.
In a thermocouple probe that has significantly inhomogeneous legs, the relationship between emf and temperature is indefinite and depends on temperature distribution along the circuit. An inhomogeneous thermocouple cannot be calibrated to arbitrarily small uncertainty. Therefore, testing for inhomogeneities is a necessary preliminary to meaningful calibration. As most significant inhomogeneity that does occur is introduced during use (and sometimes during calibration) a post-test inhomogeneity measurement should also be employed to detect degradation that might have substantially affected the data. This paper presents a practical test method that is being developed for the observation, interpretation, and application of thermoelectric inhomogeneity as a routine quality assurance measurement that is an essential complement to traditional sheathed thermocouple calibration.