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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS2012

Tile Surface Thermocouple Measurement Challenges from the Orbiter Boundary Layer Transition Flight Experiment

Hypersonic entry flight testing motivated by efforts seeking to characterize boundary layer transition on the Space Shuttle Orbiters have identified challenges in our ability to acquire high quality quantitative surface temperature measurements versus time. Five missions near the end of the Space Shuttle Program implemented a tile surface protuberance as a boundary layer trip together with tile surface thermocouples to capture temperature measurements during entry. Similar engineering implementations of these measurements on Discovery and Endeavor demonstrated unexpected measurement voltage response during the high heating portion of the entry trajectory. An assessment has been performed to characterize possible causes of the issues experienced during STS-119, STS-128, STS-131, STS-133 and STS-134 as well as similar issues encountered during other orbiter entries.

Charles H. Campbell↗
NASA NTRS1994

Applications of Thin Film Thermocouples for Surface Temperature Measurement

Thin film thermocouples provide a minimally intrusive means of measuring surface temperature in hostile, high temperature environments. Unlike wire thermocouples, thin films do not necessitate any machining of the surface, therefore leaving intact its structural integrity. Thin films are many orders of magnitude thinner than wire, resulting in less disruption to the gas flow and thermal patterns that exist in the operating environment. Thin film thermocouples have been developed for surface temperature measurement on a variety of engine materials. The sensors are fabricated in the NASA Lewis Research Center's Thin Film Sensor Lab, which is a class 1000 clean room. The thermocouples are platinum-13 percent rhodium versus platinum and are fabricated by the sputtering process. Thin film-to-leadwire connections are made using the parallel-gap welding process. Thermocouples have been developed for use on superalloys, ceramics and ceramic composites, and intermetallics. Some applications of thin film thermocouples are: temperature measurement of space shuttle main engine turbine blade materials, temperature measurement in gas turbine engine testing of advanced materials, and temperature and heat flux measurements in a diesel engine. Fabrication of thin film thermocouples is described. Sensor durability, drift rate, and maximum temperature capabilities are addressed.

Martin, Lisa C.↗
NASA NTRSDate not supplied

Preliminary 3D Simulations of Anomalous Thermocouple Coupling to Surface Electric Fields

Anomalous measurements from subsurface thermocouples have been observed during re-entry of the Orion capsule (EFT-1 plugs). These measurements are considered anomalous because the amplitude and frequency of the inferred temperature modulations are too large to be due to plausible heating processes. Consequently, it is believed the anomalies are caused by electrical interference generated by the re-entry plasma. Quantifying these effects requires several steps: modeling the external plasma flows, modeling the plasma-surface interaction, and finally modeling the surface-thermocouple coupling. This paper addresses this last step using 3D finite element simulations of a wire embedded in a weakly conductive medium.

thermocouple anomaly↗
NASA NTRS1989

Heat-Flux Sensor For Hot Engine Cylinders

Heat-flux sensor includes buried wire thermocouple and thin-film surface thermocouple, made of platinum and platinum with 13 percent rhodium. Sensor intended for use in ceramic-insulated, low-heat-rejection diesel engine at temperatures of about 1,000 K. Thermocouple junction resists environment in cylinder of advanced high-temperature diesel engine created by depositing overlapping films of Pt and 0.87 Pt/0.13 Rh on iron plug. Plug also contains internal thermocouple.

Kim, Walter S.↗
NASA NTRS1981

Preliminary study of temperature measurement techniques for Stirling engine reciprocating seals

Methods of determining the contact surface temperature in reciprocating seals are investigated. Direct infrared measurement of surface temperatures of a rod exiting a loaded cap seal or simulated seal are compared with surface thermocouple measurements. Significant cooling of the surface requires several milliseconds so that exit temperatures may be considered representative of internal contact temperatures.

Wilcock, D. F.↗
NASA NTRS1973

Complex permittivity measurements during high temperature recycling of space shuttle antenna window and dielectric heat shield materials

The research performed and the data obtained on candidate space shuttle antenna window and heat shield materials are presented. The measurement technique employs a free-space focused beam microwave bridge for obtaining RF transmission data, and a device which rotates a sample holder which is heated on one side by natural gas-air flames. The surface temperature of each sample is monitored by IR pyrometry; embedded and rear surface thermocouples are also used in obtaining temperature data. The surface of the sample undergoing test is subjected to approximately the same temperature/time profile that occurs at a proposed antenna position on the space shuttle as it re-enters. The samples are cycled through ten of these temperature profiles to determine the recycling effects. Very little change was noted in the materials due to the recycling.

Bassett, H. L.↗
NASA NTRS2012

Quantitative Infrared Image Analysis Of Thermally-Thin Cellulose Surface Temperatures During Upstream and Downstream Microgravity Flame Spread from A Central Ignition Line

Surface view calibrated infrared images of ignition and flame spread over a thin cellulose fuel were obtained at 30 Hz during microgravity flame spread tests in the 10 second Japan Microgravity Center (JAMIC). The tests also used a color video of the surface view and color images of the edge view using 35 millimeter 1600 Kodak Ektapress film at 2 Hz. The cellulose fuel samples (50% long fibers from lumi pine and 50% short fibers from birch) were made with an area density of 60 grams per square meters. The samples were mounted in the center of a 12 centimeter wide by 16 centimeter tall flow duct that uses a downstream fan to draw the air through the flow duct. Samples were ignited after the experiment package was released using a straight hot wire across the center of the 7.5 centimeter wide by 14 centimeter long samples. One case, at 1 atmosphere 35%O2 in N2, at a forced flow of 10 centimeters per second, is presented here. In this case, as the test progresses, the single flame begins to separate into simultaneous upstream and downstream flames. Surface temperature profiles are evaluated as a function of time, and temperature gradients for upstream and downstream flame spread are measured. Flame spread rates from IR image data are compared to visible image spread rate data. IR blackbody temperatures are compared to surface thermocouple readings to evaluate the effective emissivity of the pyrolyzing surface. Preheat lengths are evaluated both upstream and downstream of the central ignition point. A surface energy balance estimates the net heat flux from the flame to the fuel surface along the length of the fuel.

Olson, Sandra L.↗
NASA NTRS2013

Quantitative Infrared Image Analysis Of Simultaneous Upstream and Downstream Microgravity Flame Spread over Thermally-Thin Cellulose in Low Speed Forced Flow

The effect of low velocity forced flow on microgravity flame spread is examined using quantitative analysis of infrared video imaging. The objective of the quantitative analysis is to provide insight into the mechanisms of flame spread in microgravity where the flame is able to spread from a central location on the fuel surface, rather than from an edge. Surface view calibrated infrared images of ignition and flame spread over a thin cellulose fuel were obtained along with a color video of the surface view and color images of the edge view using 35 mm color film at 2 Hz. The cellulose fuel samples were mounted in the center of a 12 cm wide by 16 cm tall flow duct and were ignited in microgravity using a straight hot wire across the center of the 7.5 cm wide by 14 cm long samples. Four cases, at 1 atm. 35%O2 in N2, at forced flows from 2 cm/s to 20 cm/s are presented here. This flow range captures flame spread from strictly upstream spread at low flows, to predominantly downstream spread at high flow. Surface temperature profiles are evaluated as a function of time, and temperature gradients for upstream and downstream flame spread are measured. Flame spread rates from IR image data are compared to visible image spread rate data. IR blackbody temperatures are compared to surface thermocouple readings to evaluate the effective emissivity of the pyrolyzing surface. Preheat lengths and pyrolysis lengths are evaluated both upstream and downstream of the central ignition point. A surface energy balance estimates the net heat flux from the flame to the fuel surface along the length of the fuel. Surface radiative loss and gas-phase radiation from soot are measured relative to the net heat feedback from the flame. At high surface heat loss relative to heat feedback, the downstream flame spread does not occur.

Olson, S. L.↗
NASA NTRS1976

Aeroheating model advancements featuring electroless metallic plating

Discussed are advancements in wind tunnel model construction methods and hypersonic test data demonstrating the methods. The general objective was to develop model fabrication methods for improved heat transfer measuring capability at less model cost. A plated slab model approach was evaluated with cast models containing constantan wires that formed single-wire-to-plate surface thermocouple junctions with a seamless skin of electroless nickel alloy. The surface of a space shuttle orbiter model was selectively plated with scaled tiles to simulate, with high fidelity, the probable misalignments of the heatshield tiles on a flight vehicle. Initial, Mach 8 heating results indicated a minor effect of tile misalignment roughness on boundary layer transition, implying a possible relaxation of heatshield manufacturing tolerances. Some loss of the plated tiles was experienced when the model was tested at high heating rates.

Stalmach, C. J., Jr.↗
NASA NTRS1996

PICA Forebody Heatshield Qualification for the Stardust Discovery Class Mission

This paper presents the qualification of the light weight Phenolic Impregnated Carbon Ablators (PICA) as the forebody heatshield for the Stardust Discovery Class Mission. The Stardust spacecraft will be launched in early 1999 and fly by Comet Wild-2 to collect cometary and interstellar dust and return them back to earth in the Sample Return Capsule (SRC). This earth re-entry will be the fastest to date, at 12.6 km/s, and therefore requires a heatshield that can withstand very high heating rates and stagnation pressures, as well as provide the necessary insulation to the vehicle structure. The PICA material was developed as part of the Lightweight Ceramic Ablators program at NASA Ames Research Center, and was baselined as the forebody heatshield because of its low density and superior ablation and thermal performance at severe aerothermodynamic conditions. Under a Small Business Innovative Research (SBIR) program with NASA Ames, Fiber Materials, Inc. developed a process to manufacture a single-piece PICA heatshield for the forebody of the SRC, along with witness material for the fabrication of the test models. The test models were fabricated and instrumented by the staff of Lockheed Martin Astronautics in Denver, Colorado. Full body preliminary aerothermal CFD calculations were performed at NASA Ames to determine the heating and stagnation pressure conditions. The Heat shield sizing was also performed at NASA Ames by using a new material response code that accounts for the highly porous characteristics of the PICA material. The ablation and thermal performance of PICA was qualified in the NASA Ames Interaction Heating Arc Jet Facility. A total of 24 models and four test conditions were used to qualify PICA at the predicted peak heat flux, heat load, shear, and stagnation pressure conditions. Surface and in-depth temperatures were measured using optical pyrometers and thermocouples. Surface recession was measured by using a template and a height gage. Several models were tested to evaluate repair procedures, and two models were cold soaked in liquid nitrogen, prior th testing, to investigate the effect of the cold space environment on the performance of the material. In addition, material cored from a demonstration single-piece heatshield was tested to verify that the PICA process can be successfully completed on a large, complex heatshield shape.

Tran, Huy K.↗
NASA NTRS1997

Blunt Body Near-Wake Flow Field at Mach 10

Tests were conducted in a Mach 10 air flow to examine the reattachment process of a free shear layer associated with the near wake of a 70 deg half angle, spherically blunted cone having a cylindrical after body. The nominal free-stream Reynolds number based on model diameter ranged from 0.25 x l0(exp 6) to 1 x l0(exp 6) and the angle of incidence set at 0 and +/- 20 deg. The present study was designed to complement previously reported Mach 6 perfect air tests as well as results obtained in several hypervelocity facilities capable of producing real gas effects. Surface heating rates were inferred from temperature time histories from coaxial surface thermocouples on the model forebody and thin film resistance gages along the model base and cylindrical after body. Limited forebody, base, and support sting surface pressures were obtained with piezoresistive Experimental results are compared to laminar perfect gas predictions provided by a 3-0 Navier Stokes code (NSHYP). Shear layer impingement on the instrumented cylindrical after body resulted in a localized heating maximum that was 16 to 18percent of the forebody stagnation point and a factor of 2 higher than laminar predictions, suggesting a transitional or turbulent shear layer. transducers.

Horvath, Thomas↗
NASA NTRS2011

Orion Flight Test-1 Thermal Protection System Instrumentation

The Orion Crew Exploration Vehicle (CEV) was originally under development to provide crew transport to the International Space Station after the retirement of the Space Shuttle, and to provide a means for the eventual return of astronauts to the Moon. With the current changes in the future direction of the United States human exploration programs, the focus of the Orion project has shifted to the project s first orbital flight test, designated Orion Flight Test 1 (OFT-1). The OFT-1 is currently planned for launch in July 2013 and will demonstrate the Orion vehicle s capability for performing missions in low Earth orbit (LEO), as well as extensibility beyond LEO for select, critical areas. Among the key flight test objectives are those related to validation of the re-entry aerodynamic and aerothermal environments, and the performance of the thermal protection system (TPS) when exposed to these environments. A specific flight test trajectory has been selected to provide a high energy entry beyond that which would be experienced during a typical low Earth orbit return, given the constraints imposed by the possible launch vehicles. This trajectory resulted from a trade study that considered the relative benefit of conflicting objectives from multiple subsystems, and sought to provide the maximum integrated benefit to the re-entry state-of-the-art. In particular, the trajectory was designed to provide: a significant, measureable radiative heat flux to the windward surface; data on boundary transition from laminar to turbulent flow; and data on catalytic heating overshoot on non-ablating TPS. In order to obtain the necessary flight test data during OFT-1, the vehicle will need to have an adequate quantity of instrumentation. A collection of instrumentation is being developed for integration in the OFT-1 TPS. In part, this instrumentation builds upon the work performed for the Mars Science Laboratory Entry, Descent and Landing Instrument (MEDLI) suite to instrument the OFT-1 ablative heat shield. The MEDLI integrated sensor plugs and pressure sensors will be adapted for compatibility with the Orion TPS design. The sensor plugs will provide in-depth temperature data to support aerothermal and TPS model correlation, and the pressure sensors will provide a flush air data system for validation of the entry and descent aerodynamic environments. In addition, a radiometer design will be matured to measure the radiative component of the reentry heating at two locations on the heat shield. For the back shell, surface thermocouple and pressure port designs will be developed and applied which build upon the heritage of the Space Shuttle Program for instrumentation of reusable surface insulation (RSI) tiles. The quantity and location of the sensors has been determined to balance the needs of the reentry disciplines with the demands of the hardware development, manufacturing and integration. Measurements which provided low relative value and presented significant engineering development effort were, unfortunately, eliminated. The final TPS instrumentation has been optimized to target priority test objectives. The data obtained will serve to provide a better understanding of reentry environments for the Orion capsule design, reduce margins, and potentially reduce TPS mass or provide TPS extensibility for alternative missions.

Kowal, T. John↗
NASA NTRS2009

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.↗
NASA NTRS1984

Aerodynamic heating rate distributions induced by trailing edge controls on hypersonic aircraft configurations at Mach 8

Aerodynamic surface heating rate distributions in three dimensional shock wave boundary layer interaction flow regions are presented for a generic set of model configurations representative of the aft portion of hypersonic aircraft. Heat transfer data were obtained using the phase change coating technique (paint) and, at particular spanwise and streamwise stations for sample cases, by the thin wall transient temperature technique (thermocouples). Surface oil flow patterns are also shown. The good accuracy of the detailed heat transfer data, as attested in part by their repeatability, is attributable partially to the comparatively high temperature potential of the NASA-Langley Mach 8 Variable Density Tunnel. The data are well suited to help guide heating analyses of Mach 8 aircraft, and should be considered in formulating improvements to empiric analytic methods for calculating heat transfer rate coefficient distributions.

Kaufman, L. G., II↗
NASA NTRSDate not supplied

Progress on Quantitative Infrared Thermography at the NASA Langley Aerothermodynamic Laboratory

A quantitative infrared thermography technique is being developed for accurate and high-resolution measurements of surface temperature and heat flux in the hypersonic wind tunnels at NASA Langley Research Center. A hemisphere test campaign was carried out in the Langley Aerothermodynamic Laboratory 20-Inch Mach 6 Air Tunnel to assess the current performance of the technique and to identify remaining challenges. Measurements were obtained for three different model materials over a range of freestream Reynolds numbers. The raw infrared images were converted to temperature via a radiometric calibration of the camera sensor. Corrections were made for losses due to test article emissivity and window transmissivity. A preliminary uncertainty analysis yielded an estimated accuracy within 4 K at moderate viewing angles, similar to that of a standard thermocouple. Surface heat flux was obtained from the measured surface temperatures via a finite-difference solution of the one-dimensional heat equation that modeled thermal variation of the material properties. Comparisons of the measured heating to both computational and theoretical predictions demonstrated agreement within the expected uncertainty of the technique. The heat transfer measurement near the stagnation point was found to be highly sensitive to the test article emissivity, which establishes the need for improved characterization of the wind tunnel model materials for high temperature applications.

infrared thermography↗
NASA NTRS1996

Heat Transfer Experiments in the Internal Cooling Passages of a Cooled Radial Turbine Rotor

An experimental study was conducted (1) to experimentally measure, assess and analyze the heat transfer within the internal cooling configuration of a radial turbine rotor blade and (2) to obtain heat transfer data to evaluate and improve computational fluid dynamics (CFD) procedures and turbulent transport models of internal coolant flows. A 1.15 times scale model of the coolant passages within the NASA LERC High Temperature Radial Turbine was designed, fabricated of Lucite and instrumented for transient beat transfer tests using thin film surface thermocouples and liquid crystals to indicate temperatures. Transient heat transfer tests were conducted for Reynolds numbers of one-fourth, one-half, and equal to the operating Reynolds number for the NASA Turbine. Tests were conducted for stationary and rotating conditions with rotation numbers in the range occurring in the NASA Turbine. Results from the experiments showed the heat transfer characteristics within the coolant passage were affected by rotation. In general, the heat transfer increased and decreased on the sides of the straight radial passages with rotation as previously reported from NASA-HOST-sponsored experiments. The heat transfer in the tri-passage axial flow region adjacent to the blade exit was relatively unaffected by rotation. However, the heat transfer on one surface, in the transitional region between the radial inflow passage and axial, constant radius passages, decreased to approximately 20 percent of the values without rotation. Comparisons with previous 3-D numerical studies indicated regions where the heat transfer characteristics agreed and disagreed with the present experiment.

Johnson, B. V.↗
NASA NTRS1996

Blunt body near wake flow field at Mach 6

Tests were conducted in a Mach 6 flow to examine the reattachment process of an axisymmetric free shear layer associated with the near wake of a 70 deg. half angle, spherically blunted cone with a cylindrical after body. Model angle of incidence was fixed at 0 deg. and free-stream Reynolds numbers based on body diameter ranged from 0.5 x 10(exp 6) to 4 x 10(exp 6). The sensitivity of wake shear layer transition on reattachment heating was investigated. The present perfect gas study was designed to compliment results obtained previously in facilities capable of producing real gas effects. The instrumented blunted cone model was designed primarily for testing in high enthalpy hypervelocity shock tunnels in both this country and abroad but was amenable for testing in conventional hypersonic blowdown wind tunnels as well. Surface heating rates were inferred from temperature - time histories from coaxial surface thermocouples on the model forebody and thin film resistance gages along the model base and cylindrical after body. General flow feature (bow shock, wake shear layer, and recompression shock) locations were visually identified by schlieren photography. Mean shear layer position and growth were determined from intrusive pitot pressure surveys. In addition, wake surveys with a constant temperature hot-wire anemometer were utilized to qualitatively characterize the state of the shear layer prior to reattachment. Experimental results were compared to laminar perfect gas predictions provided by a 3-D Navier Stokes code (NSHYP). Shear layer impingement on the instrumented cylindrical after body resulted in a localized heating maximum that was 21 to 29 percent of the forebody stagnation point heating. Peak heating resulting from the reattaching shear layer was found to be a factor of 2 higher than laminar predictions, which suggested a transitional shear layer. Schlieren flow visualization and fluctuating voltage time histories and spectra from the hot wire surveys across the shear layer substantiate this observation. The sensitivity of surface heating to forebody roughness was characterized for a reattaching shear layer. For example, at R(sub infinity), d = 4 x 10(exp 6), when the shear layer was transitional, the magnitude of peak heating from shear layer impingement was reduced by approximately 24 percent when transition grit was applied to the forebody. The spatial location of the local peak, however, remained unchanged.

Horvath, Thomas J.↗