Heat Flux Sensor Testing

TFAWS 2001 Conference

Huntsville, AI

September 13, 2001

D.W. Clark

ED25

https://ntrs.nasa.gov/search.jsp?R=20030000748 2018-08-11T08:11:57+00:00Z

TFAws200, arObjectives

Develop secondary calibration capabilities for MSFC's Hot

Gas Facility (HGF), a Mach 4 Aerothermal Wind Tunnel.

• Evaluate ASTM slug/thinskin calorimetersagainst current HGF heat flux sensors

• Provide verification of baselined AEDC/Medtherm

gage calibrations

• Address future calibration issues involving NIST

certified radiant gages

D.W. Clark

ED25

TFAws2oo, arWhy Are NIST Calibration Standards Valuable?

• Shuttle Safety

• Thermal Protection Systems are developed,characterized, and qualified for flight using NISTcalibration standards at HGF

radiant

• Shuttle Performance

• 26% of the Space Shuttle's weight is TPS

• On the External Tank alone, a 15% reduction in

TPS increases Shuttle payload capacity by 600 pounds,representing $6,000,000 in potential payload cost savingsper Shuttle flight

D.W. Clark

ED25

MATERIALS ENVIRONMENT TEST COMPLEX

(ME

Improved Hot Gas Facility Hyperthermal Tester

i_iiiiii

ii::i:i!t!_:i_i:i

Thermal Acoustics Facility Large Scale Tensile Tester D.W. Clark

ED25

HGF Layout

/

|

\

lID

D.W. Clark

ED25

HGF Facility Description• The Marshall Space Flight Center's Improved Hot Gas Facility (IHGF) is an aerothermodynamic testing

facility ideal for Thermal Protection System materials characterization and qualification.

• A combustion driven, Mach 4 wind tunnel, with a 16 x 16 inch test section.

• Burns a lean mixture of gaseous hydrogen (GH2) and missile grade air producing total

temperatures of 1440 - 2400 °F with total pressures of 100 - 220 psia.

• A 300 kW radiant lamp system is available for plume environment simulation.

• Infrared (IR) thermal imaging/video capabilities used for collecting real-time surface

temperature measurements

• The IHGF is reasonably small, inexpensive in operation, very flexible and efficient, and is operated

with a small, highly experienced crew.

• Run times up to 300 seconds and up to 10 tests per day.

• Variable wedge angle (up to 20 degrees) model insertion system for panels up to 12" x 19".

• Can accommodate protuberance testing up to 7" x 12".

• The IHGF provides the opportunities for inexpensive screening, preliminary study, and technique

development work.

• It continues to provide MSFC and Industry with quick response capability during conceptual

design phases as well as during flight vehicle problem resolution.

• It is used for development and flight qualification of Space Shuttle External Tank and SRB TPS

D.W. Clark

ED25

Calorimeter Illustration

METCO Thin Skin

Dia = 1.5"

L =0.065 & 0.095"

Type K, #32 AWG

Ames Slug l

Dia = 0.302" ]

L =0.35"

Section View of Thin Skin Slug Calorimeter

I.........Densi_:0.323 .........Ibm/in3.....................................Specific Heati 0092 Btu/Ibm/F

D.W. Clark

ED25

Schmidt-Boelter Gage Design

\\

F_f_ure 4. Sectio_ drawt_g of Schm[dt-Boelter _i_ge,

D.W. Clark

ED25

Slug Assembly Drawing4-

DIMENSIONS IN MM

__-=.-- _q --

CALO RIMETER, £LUG

1

+D.W. Clark

ED25

Calibration Plate

D.W. Clark

ED25

Calorimetry Study Test Matrix And ChronologyPosition > 1 2 3 4 5 Tunnel

Test Condition

123

76

11 12

13 14 ..............::::::::::::::::::::::::::::::::::6:::::::::::::::::::::::::::::::::............................_::: ........_': _'.........

15 16

17 18 _i1_s!_e_4_6_SS_E_SS_

First Runs Repeat Runs TunnelTest HGF No. Date HGF No. Date Condition

Calorimeter

Legend

MT = 1/2" Medtherm S/N 107641

(Gage "MT" is always in Position 1)

0.065 = Thin Thin Skin Gage

0.095 = Thick Thin Skin Gage

SLUG = Ames Furnished Slug SIN TBD

3 HF #1 = 1/4" Medtherm SIN 667121

3 HF #2 = 3/16" Medtherm SIN 79455

3 HF #3 = AEDC SIN 2679

337 14-Jun

338 14-Jun341 14-Jun

_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_342 14-Juniiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii_iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii343 14-Juni_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i6_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i344 14-Jun

345 14-Jun346 14-Jun

i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i348 14-Jun_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_349 14-Jun

552 30-Jul

550 30-Jul549 30-Jul546 30-Jul544 30-Jul

543 30-Jul542 26-Jul541 26-Jul540 26-Jul

539 26-Jul449 12-Jul450 12-Jul451 12-Jul453 12-Jul

388 25-Jun391 25-Jun389 25-Jun390 25-Jun

MiscellaneousNotes

Gage "MT" is always in Position 1

Tests 1 2 3 and 4 5 6 are intended

to check for data repeatability.

D.W. Clark

ED25

Test Conditions

ii -i.......ii-ili!ii ii .............................................................ii1"1 L,,'._,iiiii.,_.!iiiii!!iiiii!!t..:_:!iii_iii.................................................................................................iii'1

[ J ,i''

,5i.............................ii.............i.............i.............._ii_.........?ii 0.5

i" "_......... ,.L iT/To) i _ _' _:ir "ii

0 0

0 5 10 15 20 25 30

Run Time (sec)Run Time (sec)

Tunnel Performance Tunnel EnvironmentsD.W. Clark

ED25

TFAws2oo, @lF,g,}25fFk_erm<_dy_ami._:_&H¢_._ Tra_vsfe

Data Reduction Timeline

l0

8

6

4

2

0

-2

SB Gage Output (BFS)

x

x

0 5 10 15 20

...................H2763 BTU

_H2764 BFS--

H2765 BFS

_H2766 BFS

25 30 35 40 45

Test Section Static Pressures (psia)

%.

\

= • .....

5 lO 15

/

20 25 30 35 40 45

Calori _ ete r data eva Iuated Whe n test secti on re aches

steady flow (~13 sec) Corresponding calorimeter/gage

co_padsons ade over one second ti_e interval

D.W. Clark

ED25

Calorimeter Data

2=

Q.

I-

Thinskin/Slug Thermocouple Output M ETCO Tunnel Pressures

350 _" 150 15

300

250

200

150

100

50

data-interval

slug

0 5 10 15 20 25 30 35 40

Time (sec)

.QEt_

J_¢J

o=a.

100

50

0

0 5 10 15 20

Time (sec)

10

0

25

"O0_

R'

Calorimeter Temperatures Static Pressures

D.W. Clark

ED25

Thin Skin Radial Conduction Errors

x

..c

03

03-o

o-oc

l,=

ol,=l,=

-60

-50

-40

-30

-20

-10

Gage Conduction Errors vs. Radial Distance

Qo=4 Btu/ft2/sec-70 jil...............'.................."................._".................!................._'..................':_.................'...................................._................_................'......................................":...................'................._......................................'.................._................._'=....................................'................._"................."'q

ii' 304 Stainless:: Steel °i

ii', skin thickness: L = 0.095 in _i

ii........................................... ! ..................... i..................... _............... J- .... ,_...................... Ri' Qo i i i air. "

................................ _ ................................................................................................ ,....-j_; ......... [- - -_ ..........................................

_r

::!....................[....................?...........-1211::;:.:;'i"..............Lf........._...................._L _ ......................_"="; ..................... 4" ;: .............. iir time, sec ::i

: : . ::....:_t:........._ ......................._........................ ;_

...............i:::,,_;JJ j" :4............+::_............_o u_i' '_...............................!__: _-*_-*:_*;;;'; '; '_"_°_"_*_'*_..... _,,o_..... :=o _................................,_ ....... -- ....................................................................: n;: ii...................Uu

lO i::..............,................_.,.................,_............................._,............._.................,................................_,................,..................,................._,................,_..............,.............._..............................,..............._,................_................,,.i................................ii

-0.2 0 0.2 0.4 0.6 0.8 1

Dx, radial distance from centerline (in)D.W. Clark

ED25

Thin Skin Temperatures

D.W. Clark

ED25

S-B Gage Temperatures

D.W. Clark

ED25

Calorimeter Heat Transfer

• Hot Wall Rates

dt

• Compressible Flow

Tr - Pr_ (To - T)+ T

• Cold Wall Rates

(temperature ratio)

( recovery temperature)

D.W. Clark

ED25

Measurement Repeatability

rn

O

Measurement Repeatability

125psia/1600F/0 Deg

0.095"TS

Calorimeter

Slug

4.8

4.6A

,_, 4.44.2

_ 4a

3.8

3.6

Measurement Repeatability

125psia/1600F/0 Deg

1/4" MT 3/16" MT AEDC

S-B Gage

1/2" MT

m

O

25

20

15

10

5

0

Measurement Repeatability

125psia/1600F/15 Deg

iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii

0.065" TS 0.095"TS

Calorimeter

Slug

15

lO

0

Measurement Repeatability

125ps ia/1600F/15 Deg

1/4" MT 3/16" MT AEDC

S-B Gage

1/2" MT

3.W. Clark

ED25

Measurement Comparisons

6

5

_3

0

Calodrre_ v_ _ IVt_astramms125psiaJ1600F/0 Deg

@1/2" IVlT

m 0.065"TS

[] 0.095"TS

BSlug

m 1/4" IVlT

@3/16" IVIT

mAEDC2 3 4 5

Rate Pos_on

3O

25

15

5

0

125psia/1600F/15Deg

:::::::::

1 52 3 4

@1/2' MI

m0.06_'TS

D 0.09_'TS

Dgug

m 1/4"MT

@3/16' Ml

mAEDC

Rate Position

Test Condition: 125psia/1600F/0 & 15 DegD.W. Clark

ED25

TFAws2oo, arFuture Work Planned At MSFC HGF

• Continue to develop calorimeter database

• Study combined effects of supersonic convectionand radiant heating on material response

• Calibrate In-flight measurements of heat fluxes withdissimilar material induced thermal mismatches between gageand surrounding TPS material

• Study radiant heat measurement in the presence of convective cooling

D.W. Clark

ED25