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Remote Infrared Imaging of the Space Shuttle During Hypersonic Flight: HYTHIRM Mission Operations and Coordination

The Hypersonic Thermodynamic Infrared Measurements (HYTHIRM) project has been responsible for obtaining spatially resolved, scientifically calibrated in-flight thermal imagery of the Space Shuttle Orbiter during reentry. Starting with STS-119 in March of 2009 and continuing through to the majority of final flights of the Space Shuttle, the HYTHIRM team has to date deployed during seven Shuttle missions with a mix of airborne and ground based imaging platforms. Each deployment of the HYTHIRM team has resulted in obtaining imagery suitable for processing and comparison with computational models and wind tunnel data at Mach numbers ranging from over 18 to under Mach 5. This paper will discuss the detailed mission planning and coordination with the NASA Johnson Space Center Mission Control Center that the HYTHIRM team undergoes to prepare for and execute each mission.

Schwartz, Richard J.↗

The HYTHIRM Project: Flight Thermography of the Space Shuttle During the Hypersonic Re-entry

This report describes a NASA Langley led endeavor sponsored by the NASA Engineering Safety Center, the Space Shuttle Program Office and the NASA Aeronautics Research Mission Directorate to demonstrate a quantitative thermal imaging capability. A background and an overview of several multidisciplinary efforts that culminated in the acquisition of high resolution calibrated infrared imagery of the Space Shuttle during hypervelocity atmospheric entry is presented. The successful collection of thermal data has demonstrated the feasibility of obtaining remote high-resolution infrared imagery during hypersonic flight for the accurate measurement of surface temperature. To maximize science and engineering return, the acquisition of quantitative thermal imagery and capability demonstration was targeted towards three recent Shuttle flights - two of which involved flight experiments flown on Discovery. In coordination with these two Shuttle flight experiments, a US Navy NP-3D aircraft was flown between 26-41 nautical miles below Discovery and remotely monitored surface temperature of the Orbiter at Mach 8.4 (STS-119) and Mach 14.7 (STS-128) using a long-range infrared optical package referred to as Cast Glance. This same Navy aircraft successfully monitored the Orbiter Atlantis traveling at approximately Mach 14.3 during its return from the successful Hubble repair mission (STS-125). The purpose of this paper is to describe the systematic approach used by the Hypersonic Thermodynamic Infrared Measurements team to develop and implement a set of mission planning tools designed to establish confidence in the ability of an imaging platform to reliably acquire, track and return global quantitative surface temperatures of the Shuttle during entry. The mission planning tools included a pre-flight capability to predict the infrared signature of the Shuttle. Such tools permitted optimization of the hardware configuration to increase signal-to-noise and to maximize the available dynamic range while mitigating the potential for saturation. Post flight, analysis tools were used to assess atmospheric effects and to convert the 2-D intensity images to 3-D temperature maps of the windward surface. Comparison of the spatially resolved global thermal measurements to surface thermocouples and CFD prediction is made. Successful demonstration of a quantitative, spatially resolved, global temperature measurement on the Shuttle suggests future applications towards hypersonic flight test programs within NASA, DoD and DARPA along with flight test opportunities supporting NASA's project Constellation.

Horvath, Thomas J.↗

HYTHIRM Radiance Modeling and Image Analyses in Support of STS-119, STS-125 and STS-128 Space Shuttle Hypersonic Re-entries

We provide the first geometrically accurate (i.e., 3-D) temperature maps of the entire windward surface of the Space Shuttle during hypersonic reentry. To accomplish this task we began with estimated surface temperatures derived from CFD models at integral high Mach numbers and used them, the Shuttle's surface properties and reasonable estimates of the sensor-to-target geometry to predict the emitted spectral radiance from the surface (in units of W sr-1 m-2 nm-1). These data were converted to sensor counts using properties of the sensor (e.g. aperture, spectral band, and various efficiencies), the expected background, and the atmosphere transmission to inform the optimal settings for the near-infrared and midwave IR cameras on the Cast Glance aircraft. Once these data were collected, calibrated, edited, registered and co-added we formed both 2-D maps of the scene in the above units and 3-D maps of the bottom surface in temperature that could be compared with not only the initial inputs but also thermocouple data from the Shuttle itself. The 3-D temperature mapping process was based on the initial radiance modeling process. Here temperatures were guessed for each node in a well-resolved 3-D framework, a radiance model was produced and compared to the processed imagery, and corrections to the temperature were estimated until the iterative process converged. This process did very well in characterizing the temperature structure of the large asymmetric boundary layer transition the covered much of the starboard bottom surface of STS-119 Discovery. Both internally estimated accuracies and differences with CFD models and thermocouple measurements are at most a few percent. The technique did less well characterizing the temperature structure of the turbulent wedge behind the trip due to limitations in understanding the true sensor resolution. (Note: Those less inclined to read the entire paper are encouraged to read an Executive Summary provided at the end.)

Gibson, David M.↗

A System Trade Study of Remote Infrared Imaging for Space Shuttle Reentry

A trade study reviewing the primary operational parameters concerning the deployment of imaging assets in support of the Hypersonic Thermodynamic Infrared Measurements (HYTHIRM) project was undertaken. The objective was to determine key variables and constraints for obtaining thermal images of the Space Shuttle orbiter during reentry. The trade study investigated the performance characteristics and operating environment of optical instrumentation that may be deployed during a HYTHIRM data collection mission, and specified contributions to the Point Spread Function. It also investigated the constraints that have to be considered in order to optimize deployment through the use of mission planning tools. These tools simulate the radiance modeling of the vehicle as well as the expected spatial resolution based on the Orbiter trajectory and placement of land based or airborne optical sensors for given Mach numbers. Lastly, this report focused on the tools and methodology that have to be in place for real-time mission planning in order to handle the myriad of variables such as trajectory ground track, weather, and instrumentation availability that may only be known in the hours prior to landing.

Schwartz, Richard J.↗

Infrared Imaging of Boundary Layer Transition Flight Experiments

The Hypersonic Thermodynamic Infrared Measurement (HYTHIRM) project is presently focused on near term support to the Shuttle program through the development of an infrared imaging capability of sufficient spatial and temporal resolution to augment existing on-board Orbiter instrumentation. Significant progress has been made with the identification and inventory of relevant existing optical imaging assets and the development, maturation, and validation of simulation and modeling tools for assessment and mission planning purposes, which were intended to lead to the best strategies and assets for successful acquisition of quantitative global surface temperature data on the Shuttle during entry. However, there are longer-term goals of providing global infrared imaging support to other flight projects as well. A status of HYTHIRM from the perspective of how two NASA-sponsored boundary layer transition flight experiments could benefit by infrared measurements is provided. Those two flight projects are the Hypersonic Boundary layer Transition (HyBoLT) flight experiment and the Shuttle Boundary Layer Transition Flight Experiment (BLT FE), which are both intended for reducing uncertainties associated with the extrapolation of wind tunnel derived transition correlations for flight application. Thus, the criticality of obtaining high quality flight data along with the impact it would provide to the Shuttle program damage assessment process are discussed. Two recent wind tunnel efforts that were intended as risk mitigation in terms of quantifying the transition process and resulting turbulent wedge locations are briefly reviewed. Progress is being made towards finalizing an imaging strategy in support of the Shuttle BLT FE, however there are no plans currently to image HyBoLT.

Berry, Scott A.↗

Orbiter Entry Aerodynamics Flight Testing: STS-119 and STS-125

NASA has performed entry flight testing related to boundary layer transition and turbulent heating environments during 2009. Two projects are involved in implementing the activities and acquiring flight data: 1) Orbiter BLT Flight Experiment during STS-119; and 2) Hypersonic Thermodynamic Infrared Measurements (HYTHIRM) during STS-119 and STS-125. Orbiter BLT FE has implemented tile surface thermocouples in order to provide in-situ data downstream of a fixed geometry tile protuberance. HYTHIRM has developed a framework of mission planning and aircraft based telescopic infrared measurements to provide quantitative surface temperature distributions.

Campbell, Charles H.↗

Experimental Space Shuttle Orbiter Studies to Acquire Data for Code and Flight Heating Model Validation

In an experimental study to obtain detailed heating data over the Space Shuttle Orbiter, CUBRC has completed an extensive matrix of experiments using three distinct models and two unique hypervelocity wind tunnel facilities. This detailed data will be employed to assess heating augmentation due to boundary layer transition on the Orbiter wing leading edge and wind side acreage with comparisons to computational methods and flight data obtained during the Orbiter Entry Boundary Layer Flight Experiment and HYTHIRM during STS-119 reentry. These comparisons will facilitate critical updates to be made to the engineering tools employed to make assessments about natural and tripped boundary layer transition during Orbiter reentry. To achieve the goals of this study data was obtained over a range of Mach numbers from 10 to 18, with flight scaled Reynolds numbers and model attitudes representing key points on the Orbiter reentry trajectory. The first of these studies were performed as an integral part of Return to Flight activities following the accident that occurred during the reentry of the Space Shuttle Columbia (STS-107) in February of 2003. This accident was caused by debris, which originated from the foam covering the external tank bipod fitting ramps, striking and damaging critical wing leading edge heating tiles that reside in the Orbiter bow shock/wing interaction region. During investigation of the accident aeroheating team members discovered that only a limited amount of experimental wing leading edge data existed in this critical peak heating area and a need arose to acquire a detailed dataset of heating in this region. This new dataset was acquired in three phases consisting of a risk mitigation phase employing a 1.8% scale Orbiter model with special temperature sensitive paint covering the wing leading edge, a 0.9% scale Orbiter model with high resolution thin-film instrumentation in the span direction, and the primary 1.8% scale Orbiter model with detailed thin-film resolution in both the span and chord direction in the area of peak heating. Additional objectives of this first study included: obtaining natural or tripped turbulent wing leading edge heating levels, assessing the effectiveness of protuberances and cavities placed at specified locations on the orbiter over a range of Mach numbers and Reynolds numbers to evaluate and compare to existing engineering and computational tools, obtaining cavity floor heating to aid in the verification of cavity heating correlations, acquiring control surface deflection heating data on both the main body flap and elevons, and obtain high speed schlieren videos of the interaction of the orbiter nose bow shock with the wing leading edge. To support these objectives, the stainless steel 1.8% scale orbiter model in addition to the sensors on the wing leading edge was instrumented down the windward centerline, over the wing acreage on the port side, and painted with temperature sensitive paint on the starboard side wing acreage. In all, the stainless steel 1.8% scale Orbiter model was instrumented with over three-hundred highly sensitive thin-film heating sensors, two-hundred of which were located in the wing leading edge shock interaction region. Further experimental studies will also be performed following the successful acquisition of flight data during the Orbiter Entry Boundary Layer Flight Experiment and HYTHIRM on STS-119 at specific data points simulating flight conditions and geometries. Additional instrumentation and a protuberance matching the layout present during the STS-119 boundary layer transition flight experiment were added with testing performed at Mach number and Reynolds number conditions simulating conditions experienced in flight. In addition to the experimental studies, CUBRC also performed a large amount of CFD analysis to confirm and validate not only the tunnel freestream conditions, but also 3D flows over the orbiter acreage, wing leading edge, and controlurfaces to assess data quality, shock interaction locations, and control surface separation regions. This analysis is a standard part of any experimental program at CUBRC, and this information was of key importance for post-test data quality analysis and understanding particular phenomena seen in the data. All work during this effort was sponsored and paid for by the NASA Space Shuttle Program Office at the Johnson Space Center in Houston, Texas.

Wadhams, T. P.↗

Transition Induced by Fence Geometrics on Shuttle Orbiter at Mach 10

Fence-induced transition data simulating a raised gap filler have been acquired on the wing lower surface of a Shuttle Orbiter model in the Langley 31-Inch Mach 10 Tunnel to compare with the Shuttle Boundary Layer Transition Flight and HYTHIRM Experiments, and to provide additional correlation data for the Boundary Layer Transition Tool. In a qualitative assessment, the data exhibit the expected response to all parameter variations; however, it is unclear whether fully effective tripping at the fence was ever realized at any test condition with the present model hardware. A preliminary, qualitative comparison of the ground-based transition measurements with those obtained from the STS-128 HYTHIRM imagery at Mach 15 reveal similar transition-wake response characteristics in terms of the spreading and the path along the vehicle surface.

Everhart, Joel L.↗

Application of a Near Infrared Imaging System for Thermographic Imaging of the Space Shuttle during Hypersonic Re-Entry

High resolution calibrated near infrared (NIR) imagery was obtained of the Space Shuttle s reentry during STS-119, STS-125, and STS-128 missions. The infrared imagery was collected using a US Navy NP-3D Orion aircraft using a long-range infrared optical package referred to as Cast Glance. The slant ranges between the Space Shuttle and Cast Glance were approximately 26-41 nautical miles at point of closest approach. The Hypersonic Thermodynamic Infrared Measurements (HYTHIRM) project was a NASA Langley led endeavor sponsored by the NASA Engineering Safety Center, the Space Shuttle Program Office and the NASA Aeronautics Research Mission Directorate to demonstrate a quantitative thermal imaging capability. HYTHIRM required several mission tools to acquire the imagery. These tools include pre-mission acquisition simulations of the Shuttle trajectory in relationship to the Cast Glance aircraft flight path, radiance modeling to predict the infrared response of the Shuttle, and post mission analysis tools to process the infrared imagery to quantitative temperature maps. The spatially resolved global thermal measurements made during the Shuttle s hypersonic reentry provides valuable flight data for reducing the uncertainty associated with present day ground-to-flight extrapolation techniques and current state-of-the-art empirical boundary-layer transition or turbulent heating prediction methods. Laminar and turbulent flight data is considered critical for the development of turbulence models supporting NASA s next-generation spacecraft. This paper will provide the motivation and details behind the use of an upgraded NIR imaging system used onboard a Navy Cast Glance aircraft and describe the characterizations and procedures performed to obtain quantitative temperature maps. A brief description and assessment will be provided of the previously used analog NIR camera along with image examples from Shuttle missions STS-121, STS-115, and solar tower test. These thermal observations confirmed the challenge of a long-range acquisition during re-entry. These challenges are due to unknown atmospheric conditions, image saturation, vibration etc. This provides the motivation for the use of a digital NIR sensor. The characterizations performed on the digital NIR sensor included radiometric, spatial, and spectral measurements using blackbody radiation sources and known targets. An assessment of the collected data for three Space Shuttle atmospheric re-entries, STS-119, STS-125, and STS-128, are provided along with a description of various events of interest captured using the digital NIR imaging system such as RCS firings and boundary layer transitions. Lastly the process used to convert the raw image counts to quantitative temperatures is presented along with comparisons to the Space Shuttle's onboard thermocouples.

Zalameda, Joseph N.↗

Cast Glance Near Infrared Imaging Observations of the Space Shuttle During Hypersonic Re-Entry

High resolution calibrated infrared imagery of the Space Shuttle was obtained during hypervelocity atmospheric entries of the STS-119, STS-125 and STS128 missions and has provided information on the distribution of surface temperature and the state of the airflow over the windward surface of the Orbiter during descent. This data collect was initiated by NASA s Hypersonic Thermodynamic Infrared Measurements (HYTHIRM) team and incorporated the use of air- and land-based optical assets to image the Shuttle during atmospheric re-entry. The HYTHIRM objective is to develop and implement a set of mission planning tools designed to establish confidence in the ability of an existing optical asset to reliably acquire, track and return global quantitative surface temperatures of the Shuttle during entry. On Space Shuttle Discovery s STS-119 mission, NASA flew a specially modified thermal protection system tile and instrumentation package to monitor heating effects from boundary layer transition during re-entry. On STS-119, the windward airflow on the port wing was deliberately disrupted by a four-inch wide and quarter-inch tall protuberance built into the modified tile. In coordination with this flight experiment, a US Navy NP-3D Orion aircraft was flown 28 nautical miles below Discovery and remotely monitored surface temperature of the Orbiter at Mach 8.4 using a long-range infrared optical package referred to as Cast Glance. Approximately two months later, the same Navy Cast Glance aircraft successfully monitored the surface temperatures of the Orbiter Atlantis traveling at approximately Mach 14.3 during its return from the successful Hubble repair mission. In contrast to Discovery, Atlantis was not part of the Boundary Layer Transition (BLT) flight experiment, thus the vehicle was not configured with a protuberance on the port wing. In September 2009, Cast Glance was again successful in capturing infrared imagery and monitoring the surface temperatures on Discovery s next flight, STS-128. Again, NASA flew a specially modified thermal protection system tile and instrumentation package to monitor heating effects from boundary layer transition during re-entry. During this mission, Cast Glance was able to image laminar and turbulent flow phenomenology optimizing data collection for Mach 14.7. The purpose of this paper is to describe key elements associated with STS-119/125/128 mission planning and execution from the perspective of the Cast Glance flight crew that obtained the imagery. The paper will emphasize a human element of experience, expertise and adaptability seamlessly coupled with Cast Glance system and sensor technology required to manually collect the required imagery. Specific topics will include a near infrared (NIR) camera upgrade that was implemented just prior to the missions, how pre-flight radiance modeling was utilized to optimize the IR sensor configuration, communications, the development of aircraft test support positions based upon Shuttle trajectory information, support to contingencies such as Shuttle one orbit wave-offs/west coast diversions and then the Cast Glance perspective during an actual Shuttle imaging mission.

Tack, Steve↗

Hypersonic Navier Stokes Comparisons to Orbiter Flight Data

Hypersonic chemical nonequilibrium simulations of low earth orbit entry flow fields are becoming increasingly commonplace as software and computational capabilities become more capable. However, development of robust and accurate software to model these environments will always encounter a significant barrier in developing a suite of high quality calibration cases. The US3D hypersonic nonequilibrium Navier Stokes analysis capability has been favorably compared to a number of wind tunnel test cases. Extension of the calibration basis for this software to Orbiter flight conditions will provide an incremental increase in confidence. As part of the Orbiter Boundary Layer Transition Flight Experiment and the Hypersonic Thermodynamic Infrared Measurements project, NASA is performing entry flight testing on the Orbiter to provide valuable aerothermodynamic heating data. An increase in interest related to orbiter entry environments is resulting from this activity. With the advent of this new data, comparisons of the US3D software to the new flight testing data is warranted. This paper will provide information regarding the framework of analyses that will be applied with the US3D analysis tool. In addition, comparisons will be made to entry flight testing data provided by the Orbiter BLT Flight Experiment and HYTHIRM projects. If data from digital scans of the Orbiter windward surface become available, simulations will also be performed to characterize the difference in surface heating between the CAD reference OML and the digitized surface provided by the surface scans.

Campbell, Charles H.↗

Hypersonic Navier-Stokes Comparisons to Orbiter Flight Data

During the STS-119 flight of Space Shuttle Discovery, two sets of surface temperature measurements were made. Under the HYTHIRM program3 quantitative thermal images of the windward side of the Orbiter with a were taken. In addition, the Boundary Layer Transition Flight Experiment 4 made thermocouple measurements at discrete locations on the Orbiter wind side. Most of these measurements were made downstream of a surface protuberance designed to trip the boundary layer to turbulent flow. In this paper, we use the US3D computational fluid dynamics code to simulate the Orbiter flow field at conditions corresponding to the STS-119 re-entry. We employ a standard two-temperature, five-species finite-rate model for high-temperature air, and the surface catalysis model of Stewart.1 This work is similar to the analysis of Wood et al . 2 except that we use a different approach for modeling turbulent flow. We use the one-equation Spalart-Allmaras turbulence model8 with compressibility corrections 9 and an approach for tripping the boundary layer at discrete locations. In general, the comparison between the simulations and flight data is remarkably good

Candler, Graham V.↗

Comparison of CFD Predictions with Shuttle Global Flight Thermal Imagery and Discrete Surface Measurements

Surface temperature measurements from the STS-119 boundary-layer transition experiment on the space shuttle orbiter Discovery provide a rare opportunity to assess turbulent CFD models at hypersonic flight conditions. This flight data was acquired by on-board thermocouples and by infrared images taken off-board by the Hypersonic Thermodynamic Infrared Measurements (HYTHIRM) team, and is suitable for hypersonic CFD turbulence assessment between Mach 6 and 14. The primary assessment is for the Baldwin-Lomax and Cebeci-Smith algebraic turbulence models in the DPLR and LAURA CFD codes, respectively. A secondary assessment is made of the Shear-Stress Transport (SST) two-equation turbulence model in the DPLR code. Based upon surface temperature comparisons at eleven thermocouple locations, the algebraic-model turbulent CFD results average 4% lower than the measurements for Mach numbers less than 11. For Mach numbers greater than 11, the algebraic-model turbulent CFD results average 5% higher than the three available thermocouple measurements. Surface temperature predictions from the two SST cases were consistently 3 4% higher than the algebraic-model results. The thermocouple temperatures exhibit a change in trend with Mach number at about Mach 11; this trend is not reflected in the CFD results. Because the temperature trends from the turbulent CFD simulations and the flight data diverge above Mach 11, extrapolation of the turbulent CFD accuracy to higher Mach numbers is not recommended.

Wood, William A.↗

Thermographic Imaging of the Space Shuttle During Re-Entry Using a Near Infrared Sensor

High resolution calibrated near infrared (NIR) imagery of the Space Shuttle Orbiter was obtained during hypervelocity atmospheric re-entry of the STS-119, STS-125, STS-128, STS-131, STS-132, STS-133, and STS-134 missions. This data has provided information on the distribution of surface temperature and the state of the airflow over the windward surface of the Orbiter during descent. The thermal imagery complemented data collected with onboard surface thermocouple instrumentation. The spatially resolved global thermal measurements made during the Orbiter s hypersonic re-entry will provide critical flight data for reducing the uncertainty associated with present day ground-to-flight extrapolation techniques and current state-of-the-art empirical boundary-layer transition or turbulent heating prediction methods. Laminar and turbulent flight data is critical for the validation of physics-based, semi-empirical boundary-layer transition prediction methods as well as stimulating the validation of laminar numerical chemistry models and the development of turbulence models supporting NASA s next-generation spacecraft. In this paper we provide details of the NIR imaging system used on both air and land-based imaging assets. The paper will discuss calibrations performed on the NIR imaging systems that permitted conversion of captured radiant intensity (counts) to temperature values. Image processing techniques are presented to analyze the NIR data for vignetting distortion, best resolution, and image sharpness. Keywords: HYTHIRM, Space Shuttle thermography, hypersonic imaging, near infrared imaging, histogram analysis, singular value decomposition, eigenvalue image sharpness

Zalameda, Joseph N.↗

TPSAS-NF1676L-13013-DND

Description, capabilities and utilization of the NASA Langley Aerothermodynamics Laboratory (LAL) are presented. The LAL consists of four hypersonic, blow-down-to-vacuum wind tunnels that collectively provide a range of Mach number from 6 to 10 (18 simulation), unit Reynolds number from 0.05 to 8 million per foot and, most importantly for blunt configurations, normal shock density ratio from 4 to 12. These wide ranges of hypersonic simulation parameters are due, in part, to the use of two different test gases (air and tetrafluoromethane, CF4), thereby making the facilities unique. The complex represents half of the conventional (as opposed to impulse) -type hypersonic wind tunnels operational in this country. LAL facilities are used to assess and optimize the hypersonic aerodynamic performance and aeroheating characteristics of aerospace vehicle concepts and to provide benchmark aerodynamic/aeroheating data for generating the flight aerodynamic databook and final design of the thermal protection system (TPS). Modifications and enhancements of LAL hardware components and instrumentation have been pursued to increase capability, reliability, and productivity in support of programmatic goals. The facilities are utilized to generate essentially all of the experimental hypersonic aerodynamic and aeroheating information for high-priority, fast-paced Agency programs and were a major contributor to the Shuttle Columbia Accident Investigation, space shuttle Return-to-Flight program and Hypersonic Thermodynamic Infrared Measurements (HYTHIRM) project. The LAL has also contributed to the development of the Orion Crew Exploration Vehicle, Ares launch system, Mars Science Laboratory, Genesis Sample Return Capsule and supported DOD programs including HIFiRE, X-37, Falcon HTV-2 and X-51A.

John R Micol↗

From Wind Tunnels to Flight Vehicles: Visualization and quantitative measurements supporting NASA’s space program

NASA’s Space Launch System (SLS) and Orion Crew Module have been studied in wind tunnels using the planar laser-induced fluorescence (PLIF) technique for flow visualization and quantitative thermometry and in flight using high-resolution imagery and quantitative infrared surface heating measurements. This paper reviews both types of measurements. OCIS codes: (120.1740) Combustion diagnostics; (300.2530) Fluorescence, laser-induced; (110.3080) Infrared imaging.

Planar Laser-Induced Fluorescence (PLIF)↗