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Simplified theoretical approaches are shown, based on hypersonic similarity boundary-layer theory, which allow reasonably accurate estimates to be made of the surface pressures on plates on which viscous effects are important. The consideration of viscous effects includes the cases where curved surfaces, stream pressure gradients, and leadingedge bluntness are important factors.
Microelectromechanical systems (MEMS) embodies the integration of sensors, actuators, and electronics on a single substrate using integrated circuit fabrication techniques and compatible bulk and surface micromachining processes. Silicon and its derivatives form the material base for the MEMS technology. MEMS devices, including microsensors and microactuators, are attractive because they can be made small (characteristic dimension about 100 microns), be produced in large numbers with uniform performance, include electronics for high performance and sophisticated functionality, and be inexpensive. For aerodynamic measurements, it is preferred that sensors be small so as to approximate measurement at a point, and in fact, MEMS pressure sensors, wall shear-stress sensors, heat flux sensors and micromachined hot wires are nearing application. For the envisioned application to wind tunnel models, MEMS sensors can be placed on the surface or in very shallow grooves. MEMS devices have often been fabricated on stiff, flat silicon substrates, about 0.5 mm thick, and therefore were not easily mounted on curved surfaces. However, flexible substrates are now available and heat-flux sensor arrays have been wrapped around a curved turbine blade. Electrical leads can also be built into the flexible substrate. Thus MEMS instrumented wind tunnel models do not require deep spanwise grooves for tubes and leads that compromise the strength of conventionally instrumented models. With MEMS, even the electrical leads can potentially be eliminated if telemetry of the signals to an appropriate receiver can be implemented. While semiconductor silicon is well known for its electronic properties, it is also an excellent mechanical material for MEMS applications. However, silicon electronics are limited to operations below about 200 C, and silicon's mechanical properties start to diminish above 400 C. In recent years, silicon carbide (SiC) has emerged as the leading material candidate for applications in high temperature environments and can be used for high-temperature MEMS applications. With SiC, diodes and more complex electronics have been shown to operate to about 600 C, while the mechanical properties of SiC are maintained to much higher temperatures. Even when MEMS devices show benefits in the laboratory, there are many packaging challenges for any aeronautics application. Incorporating MEMS into these applications requires new approaches to packaging that goes beyond traditional integrated circuit (IC) packaging technologies. MEMS must interact mechanically, as well as electrically with their environment, making most traditional chip packaging and mounting techniques inadequate. Wind tunnels operate over wide temperature ranges in an environment that is far from being a 'clean-room.' In flight, aircraft are exposed to natural elements (e.g. rain, sun, ice, insects and dirt) and operational interferences(e.g. cleaning and deicing fluids, and maintenance crews). In propulsion systems applications, MEMS devices will have to operate in environments containing gases with very high temperatures, abrasive particles and combustion products. Hence deployment and packaging that maintains the integrity of the MEMS system is crucial. This paper presents an overview of MEMS fabrication and materials, descriptions of available sensors with more details on those being developed in our laboratories, and a discussion of sensor deployment options for wind tunnel and flight applications.
Surface and gap pressures and heating-rate distributions were obtained for simulated Thermal Protection System (TPS) tile arrays on the curved surface test apparatus of the Langley 8-Foot High Temperature Tunnel at Mach 6.6. The results indicated that the chine gap pressures varied inversely with gap width because larger gap widths allowed greater venting from the gap to the lower model side pressures. Lower gap pressures caused greater flow ingress from the surface and increased gap heating. Generally, gap heating was greater in the longitudinal gaps than in the circumferential gaps. Gap heating decreased with increasing gap depth. Circumferential gap heating at the mid-depth was generally less than about 10 percent of the external surface value. Gap heating was most severe at local T-gap junctions and tile-to-tile forward-facing steps that caused the greatest heating from flow impingement. The use of flow stoppers at discrete locations reduced heating from flow impingement. The use of flow stoppers at discrete locations reduced heating in most gaps but increased heating in others. Limited use of flow stoppers or gap filler in longitudinal gaps could reduce gap heating in open circumferential gaps in regions of high surface pressure gradients.
An investigation is conducted of a case of axisymmetric bodies in which the application of main interest is an inlet, possibly with centerbody and ring vanes. The technique employed makes use of curved surface elements and a source density which varies over the element. Such an approach is designated a higher-order implementation. Questions of surface element geometry are discussed along with the computation of the induced velocity matrices and the organization of the calculation. The calculated results are compared with analytic solutions.
Objective lens produces a backwardly curving image of a star field that matches the similarly curved surface of the photocathode of an image dissector tube. Lens eliminates the need for a fiber-optics translation between the flat plane image and curved photocathode.
With a goal of reducing jet engine weight, simulations of a fan blade containment system with an alternate geometry were tested and analyzed. A projectile simulating a fan blade was shot at two alternate geometry containment case configurations using a gas gun. The first configuration was a flat plate representing a standard case configuration. The second configuration was a flat plate with a radially convex curve section at the impact point. The curved surface was designed to force the blade to deform plastically, dissipating energy before the full impact of the blade is received by the plate. The curved case was able to tolerate a higher impact velocity before failure. The computational model was developed and correlated with the tests and a weight savings assessment was performed. For the particular test configuration used in this study the ballistic impact velocity of the curved plate was approximately 60 m/s (200 ft/s) greater than that of the flat plate. For the computational model to successfully duplicate the test, the very high strain rate behavior of the materials had to be incorporated.
Surface topography, which significantly affects the performance of many industrial components, is normally measured with diamond-tip profilometry over small areas or with optical scattering methods over larger areas. To develop air-coupled surface profilometry, the NASA Glenn Research Center at Lewis Field initiated a Space Act Agreement with Sonix, Inc., through two Glenn programs, the Advanced High Temperature Engine Materials Program (HITEMP) and COMMTECH. The work resulted in quantitative surface topography profiles obtained using only high-frequency, focused ultrasonic pulses in air. The method is nondestructive, noninvasive, and noncontact, and it does not require light-reflective surfaces. Air surface profiling may be desirable when diamond-tip or laserbased methods are impractical, such as over large areas, when a significant depth range is required, or for curved surfaces. When the configuration is optimized, the method is reasonably rapid and all the quantitative analysis facilities are online, including two- and three-dimensional visualization, extreme value filtering (for faulty data), and leveling.
Surface heat transfer rates have been measured for several different flows on an isothermal, convexly curved surface. The freestream velocity, boundary layer thickness, acceleration parameter, and unheated starting length were varied systematically, and both turbulent and transitional boundary layers were studied. The effect of convex curvature on heat transfer rates is significant with Stanton numbers reduced 20-25% below flat wall values for the same enthalpy thickness Reynolds number. Heat transfer rates recovered slowly on a flat wall downstream of the curved wall, and after 60 cm, the Stanton numbers were still 15-20% below flat wall values. The behavior of the boundary layer suggests the existence of an asymptotic condition. Boundary layer thickness, freestream velocity, and boundary layer maturity affect the initial response to the introduction of curvature and the rate at which the asymptotic state is approached. Convex curvature appears to increase the boundary layer's sensitivity to acceleration; it also delays and retards transition. Near-laminar or early-transitional boundary layers recover from curvature rapidly, whereas late-transitional and mature boundary layers recover slowly.
Proposed technique generates pictures of curved surfaces. Object ultrasonically scanned in raster pattern generated by scanning transmitter/receiver. Receiver turned on at frequent intervals to measure depth variations of scanned object. Used for medical diagnoses by giving images of small curved objects as cornea. Adaptable to other types of reflection measurementsystems such as sonar and radar.
The algorithm for surface modeling and volume grid generation using parametric Non-Uniform Rational B-splines (NURBS) geometric representation are presented. The enhanced re-parameterization algorithm which can yield a desired physical distribution on the curve, surface, and volume is also presented. This approach bridges the gap between computer aided design surface/volume definition and surface/volume grid generation.
Wide-angle heliospheric imagers such as those carried on the SMEI and STEREO spacecraft require highly effective baffle systems to exclude diffracted light from the solar disk as well as other sources of stray light. Buffington (2000, Appl. Opt. 39, 2683-2686) has proposed replacing multi-vane baffle systems with a curved surface that can be thought of as the limiting case of closely spaced vanes. Buffington s experimental data showed that the diffractive performance of a continuous baffle is consistent with the limiting form expected from multi-vane diffraction on dimensional grounds, but a detailed prediction was not possible because multi-vane diffraction calculations assume that the diffractive edges act independently, an assumption that breaks down for a continuous surface. I describe analytic calculations of diffraction from a smooth rounded surface based on the approach of Vogler (1985, Radio Sci. 20, 582-590).
Unitary array of sensors measures temperatures at points distributed over designated area on surface. Useful in measuring surface temperatures of aerodynamic models and thermally controlled objects. Made of combination of integrated-circuit microchips and film circuitry. Temperature-sensing chips scanned at speeds approaching 10 kHz. Operating range minus 40 degrees C to 120 degrees C. Flexibility of array conforms to curved surfaces. Multiplexer eliminates numerous monitoring cables. Control of acquisition and recording of data effected by connecting array to microcomputers via suitable interface circuitry.
This paper reviews the MDA independent research and development (IRAD) efforts since 1986 in the development of two distinctly different approaches to on-orbit tube repair: (1) one-piece mechanical tube fittings that are forced, under pressure, onto the tube outer surface to effect the repair; and (2) electron beam weldings as demonstrated with the Paton-developed universal hand tool (UHT) space welding system for the repair of fluid lines and tubular components. Other areas of potential on-orbit repair using the UHT include damage to the flat or curved surfaces of habitation modules and truss assemblies. This paper will also address MDA evaluation of the Paton UHT system for on-orbit coating, cleaning, brazing, and cutting of metals. MDA development of an on-orbit compatible nondestructive evaluation (NDE) system for the inspection of tube welds is an important part of this complete space welding capability and will be discussed in a separate paper.
In this presentation, the authors address topics relevant to higher order modeling using hybrid BEM/FEM formulations. The first of these is the limitation on convergence rates imposed by geometric modeling errors in the analysis of scattering by a dielectric sphere. The second topic is the application of an Incomplete LU Threshold (ILUT) preconditioner to solve the linear system resulting from the BEM/FEM formulation. The final tOpic is the application of the higher order BEM/FEM formulation to antenna modeling problems. The authors have previously presented work on the benefits of higher order modeling. To achieve these benefits, special attention is required in the integration of singular and near-singular terms arising in the surface integral equation. Several methods for handling these terms have been presented. It is also well known that achieving ~he high rates of convergence afforded by higher order bases may als'o require the employment of higher order geometry models. A number of publications have described the use of quadratic elements to model curved surfaces. The authors have shown in an EFIE formulation, applied to scattering by a PEC .sphere, that quadratic order elements may be insufficient to prevent the domination of modeling errors. In fact, on a PEC sphere with radius r = 0.58 Lambda(sub 0), a quartic order geometry representation was required to obtain a convergence benefi.t from quadratic bases when compared to the convergence rate achieved with linear bases. Initial trials indicate that, for a dielectric sphere of the same radius, - requirements on the geometry model are not as severe as for the PEC sphere. The authors will present convergence results for higher order bases as a function of the geometry model order in the hybrid BEM/FEM formulation applied to dielectric spheres. It is well known that the system matrix resulting from the hybrid BEM/FEM formulation is ill -conditioned. For many real applications, a good preconditioner is required to obtain usable convergence from an iterative solver. The authors have examined the use of an Incomplete LU Threshold (ILUT) preconditioner . to solver linear systems stemming from higher order BEM/FEM formulations in 2D scattering problems. Although the resulting preconditioner provided aD excellent approximation to the system inverse, its size in terms of non-zero entries represented only a modest improvement when compared with the fill-in associated with a sparse direct solver. Furthermore, the fill-in of the preconditioner could not be substantially reduced without the occurrence of instabilities. In addition to the results for these 2D problems, the authors will present iterative solution data from the application of the ILUT preconditioner to 3D problems.
Thin film thermocouples for measuring material surface temperature have been previously demonstrated on several material systems and in various hostile test environments. A well-developed thin film fabrication procedure utilizing shadow masking for patterning the sensors elements had produced thin films with sufficient durability for applications in high temperature and pressure environments that exist in air-breathing and hydrogen-fueled burner rig and engine test facilities. However, while shadow masking had been a reliable method for specimens with flat and gently curved surfaces, it had not been consistently reliable for use on test components with sharp contours. This work reports on the feasibility of utilizing photolithography processing for patterning thin film thermocouples. Because this patterning process required changes in the thin film deposition process from that developed for shadow masking, the effect of these changes on thin film adherence during burner rig testing was evaluated. In addition to the results of changing the patterning method, the effects on thin film adherence of other processes used in the thin film fabrication procedure is also presented.
An analytical study of the breakup, burning, and ignition of liquid fuels injected transversely into a hot air stream is conducted. The non-reacting liquid jet breakup location is determined by the local sonic point criterion. Two models, one employing analysis of an elliptical jet cross-section and the other employing a two-dimensional blunt body to represent the transverse jet, were used for sonic point calculations. An auxiliary criterion based on surface tension stability is used as a separate means of determining the breakup location. For the reacting liquid jet problem, a diffusion flame supported by a one-step chemical reaction within the gaseous boundary layer is solved along the ellipse surface in subsonic cross flow. Typical flame structures and concentration profiles were calculated for various locations along the jet cross-section as a function of upstream Mach numbers. The integration reaction rate along the jet cross-section is used to predict ignition position, which is found to be situated near the stagnation point. While a multi-step reaction is needed to represent the ignition process more accurately, the present calculation does yield reasonable predictions concerning ignition along a curved surface.
Acoustic receptivity of a Blasius boundary layer in the presence of distributed surface irregularities is investigated analytically. It is shown that, out of the entire spatial spectrum of the surface irregularities, only a small band of Fourier components can lead to an efficient conversion of the acoustic input at any given frequency to an unstable eigenmode of the boundary layer flow. The location, and width, of this most receptive band of wavenumbers corresponds to a relative detuning of O(R sub l.b.(exp -3/8)) with respect to the lower-neutral instability wavenumber at the frequency under consideration, R sub l.b. being the Reynolds number based on a typical boundary-layer thickness at the lower branch of the neutral stability curve. Surface imperfections in the form of discrete mode waviness in this range of wavenumbers lead to initial instability amplitudes which are O(R sub l.b.(exp 3/8)) larger than those caused by a single, isolated roughness element. In contrast, irregularities with a continuous spatial spectrum produce much smaller instability amplitudes, even compared to the isolated case, since the increase due to the resonant nature of the response is more than that compensated for by the asymptotically small band-width of the receptivity process. Analytical expressions for the maximum possible instability amplitudes, as well as their expectation for an ensemble of statistically irregular surfaces with random phase distributions, are also presented.
The application of Circulation Control to the nacelle of a shrouded fan is proposed as a means to enhance off-design performance of the shrouded fan. Typically, a fixed geometry shroud is efficient at a single operating condition. Modifying circulation about the fixed geometry is proposed as a means to virtually morph the shroud without moving surfaces. This approach will enhance off-design-point performance with minimal complexity, weight, and cost. Termed the Morphing Nacelle, this concept provides an attractive propulsion option for Vertical Take-off and Landing (VTOL) aircraft, such conceptual Personal Air Vehicle (PAV) configurations proposed by NASA. An experimental proof of concept investigation of the Morphing Nacelle is detailed in this paper. A powered model shrouded fan model was constructed with Circulation Control (CC) devices integrated in the inlet and exit of the nacelle. Both CC devices consisted of an annular jet slot directing a jet sheet tangent to a curved surface, generally described as a Coanda surface. The model shroud was tailored for axial flight, with a diffusing inlet, but was operated off-design condition as a static lifting fan. Thrust stand experiments were conducted to determine if the CC devices could effectively improve off-design performance of the shrouded fan. Additional tests were conducted to explore the effectiveness of the CC devices a means to reduce peak static pressure on the ground below a lifting fan. Experimental results showed that off-design static thrust performance of the model was improved when the CC devices were employed under certain conditions. The exhaust CC device alone, while effective in diffusing the fan exhaust and improving weight flow into shroud inlet, tended to diminish performance of the fan with increased CC jet momentum. The inlet CC device was effective at reattaching a normally stalled inlet flow condition, proving an effective means of enhancing performance. A more dramatic improvement in static thrust was obtained when the inlet and exit CC devices were operated in unison, but only over a limited range of CC jet momentum. Operating the nacelle inlet and exit CC devices together proved very effective in reducing peak ground plane static pressure, while maintaining static thrust. The Morphing Nacelle concept proved effective at enhancing off-design performance of the model; however, additional investigation is necessary to generalize the results.