19760023195.Pdf

00000002-TSA03 Aerotherm FR-75-135 Final Report DEVELOPMENTOFTPSFLIGHTTEST • ANDOPERATIONALINSTRUMENTATION by K. R. Carnahan, G. J. Hartman, and G. J. Neuner ,_ AerothermDivision/AcurexCorporation 485 ClydAvenue Mountai_View,California94042 preparedfor NATIONALAERONAUTICSAND SPACEADMINISTRATION _..; January1975 ContractNAS9-13543 JohnsonSpacecraftCenter Houston,Texas ,' 00000002-TSA04 i' } ? FOREWORD l This final report was prepared by the Acurex Corporation,Aerotherm Division, for NASA/JSC Contract No. NASg-13543, Developmentof TPS Flight Test and Operational fii Instrumentation. This work was performed under the direction of the Thermal Tech- 1 nology Branch of the Structuresand Mechanics Division witflMr. James E. Pavlosky as the Program Director. 1 'i The following individualswere directly responsible for perfon,ing the proqram tasks and in the preparationof this final report: Joe Hartman, Project Enqineer, Design and Testing, and Gary Neuner, Data Reduction, Design Analysis. This report is arranged in accordancewith the three major tasks perfon,ed under this contract during the period 25 June 1973 through 25 May 1974. iii ! 00000002-TSA05 ABSTRACT Tl_rmal and flow sensor instrumentationwas developed for use as an integral. _ part of the Space Shuttle orbitor reusable thermal protectionsystem. The effort i • was performed in three tasks: Task 1 to perform a study to determine the optimum instrumentsand instrumentinstallationsfor the Space Shuttle orbitor RSI and RCC TPS, Task 2 to perform tests arid/oranalysis to determine the instrunlentinstalla- tions to minimize measurementerrors, and Task 3 to conduct analysis using data from . the test program for comparisonto analyticalmethods. In Task l, a detailed review of existing state of the art instrumentationin industrywas performed to determine the baseline for the departure of the researcheffort. From this information,detailed criteria for then_al protectionsystem instrumentaLionwere developed. A preliminarydesign study conducted on heat flux, temperature,and pressure measure- meritsrevealeda number of optimum approachesto the instrunlentationboth for the RCC and RSI TPS areas. In-depth temperaturemeasurementswere found to be best achieved through the use of chromel/alumel(type K) and platinum-platinum/13percent rhodium (type R) thermocouplescontained in plugs of the RSI material measuring no more than 0.0245 meter (l inch) in diameter with the thermocouplewire contained in a helicoil configuration. For cold wall heat flux measurements it was determined that the augmented Gardon gage concept representedthe best approach based on the design criteria for ruggedness,sensitivity,repeatability, calibration,time constant, handling, and installationconstraints. Testing verified both qualitativelyand quantitatively that the predictiontechniquesemployed ;o define the boundary layer perturbations were accurate. Under Task 2, preliminarytesting was performed on the thermocouple and cold wall heat flux gage design concepts for use in the RSl material and to a lesser extent on thermocoupletemperaturemeasurementconcepts for use on the RCC material. Testing and analysis indicated that for monitoring transient temperature historieson RCC, the flame sprayed alumina attachmenttechnique is preferred. RCC testing Further demonstrateda surface catalycity efficiencyof approximately50 percent. The recommendedtherlnocouplematerial for the RCC measurements is p]atinum- platinum/13percent rhodium (type R), with leads insulatedwith aluminum oxide in an inconel sheath. Finally, testing revealedthe damage to the RSI TPS coating would easily occur if extreme care were not exercised in instrumentinstallation. Vibration and acoustic environmentaleffects upon calorimeterinstallationswere not addressed in this program. Reconmlendationswere made to address these and other related design constraintproblems and to integrate this into the overall shuttle TPS development activity. :J ,, o." 00000002-TSA06 TABLEOFCONTENTS Section P_a_Le l SUMMARY l 2 TECHNICALDISCUSSIONOF TASKS 3 2.l Introduction 3 2.2 Task l - InstrumentationInstAllationStudy 4 : 2.2.1 Reviewof ExistingInstrumentation 4 : 2.2.2 DesignCriteria 6 : " 2.5.3 Design 7 2.2.4 MeasurementErrorAnalysis 53 i 2.2.5 InstallationEvaluation 77 2.3 Task2 - Testing 84 2.3.1 TestRequirenents 84 2.3.2 Test Program 85 2.3.3 TestResults 8H 2.4 Task 3 - DataReductionand Analysis ]o& 2.4.1 Definitionof BoundaryConditions I06 2.4.2 AnalyticalComparisonswithMeasuredInstrumentation Response I07 3 CONCLUSIONSAND RECOMMENDATIONS 120 APPENDIXA - PARAMETRICSTEADYSTATETHERMOCOUPLE ERRORANALYSISRESULTS 123 REFERENCES 130 DISTRIBUTION 13_ p.t4,h_L_.'i_XlP,'4G._GBBI,?,L_........ ,, ,,'..,',:_ vii 00000002-TSA07 LISTOF ILLUSTRATIONS Referenceshuttle body locations B 2 Reentryprofile g 3 Reentryprofile I0 I w 4 Reentryprofile 11 i 5 Reentry profiI_ 12 1] 6 Reentryprofile 13 7 Reentryprofile 14 8 Reentry profile 15 g Reentryprofile 16 lO Reentryprofile 17 11 Reentryprofile 18 12 Reentryprofile 19 13 Reentryprofile ?0 14 Reentryprofile 21 ] 15 Reentryprofile 22 ! 16 Reentryprofile 23 | 17 Thermopile-typeGardongage 33 j 18 Equilibriumslug,possiblemourttingconfiguration 40 19 Equilibriumslug timecOnStants 42 i 20 Typicalthermocoupleinstallationconfiguration 49 ! 21 Proposedp_essureportconfiguration 54 22 Reentryprofile 55 23 CalorimeterresponsetO B.P.B.idealized- heatingprofilefor i variouscalorimetertimeconstants 57 24 Sensorerrordue to thermallag versussensortimeconstant for a rampedheatingprofile 58 25 Calorimetercoldwall boundarylayerperturbation 60 26 Sensitivityof heatfluxmeasurementsto boundarylayer perturbatio_ 61 viii _: 00000002-TSA08 LIST OF ILLUSTRATIONS (Continued) N_,_.bpr Ea._ 27 S_n_itivi_yof heat flux measurement errors to cold guard rin._] 62 }!B Gold wall boundary layer p_rturbationanalysis 63 29 Cold wall boundary layer perturbationanalysis 64 _ 30 Cold wall boundary layer perturbationanalysis 65 #i! 31 Cold wall boundary layer heating augmentation analysi_ 67 32 Simplifiedl-dimenslonalmodel used to obtain approximate '4 thermocoupleattachmenterror magnitudes 6_ 33 Thermocoupleattachmenterror for varying cement tllickness 69 ! 34 Configurationfor fin analysis 71 " 35 Sensitivityof conduction induced errors to relative thermocouple 1ocation 72 36 Measurementsensitivity to wire diam., land length, and thermoelement 73 I 37 Thermocouple configurationdefinition 75 I !, 38 Measurement sensitivityto land length, transient analysis 7}I 39 Sensitivityof the response characteristicto land length 79 ; 40 HRSI thermocoupleinstallation 81 41 Garden gage/heat sink installationfor Task 2 testing _3 42 Flat face stagnationpoint model 86 43 30° half angle wedge model 87 44 Calculatedtest sample property distribution - stagnation point mn _el 90 45 Wedge model surface conditions 91 46 Unperturbedmaterial response 94 47 Unperturbedmaterial response 95 ,_ 48 Unperturbedmaterial response 96 : 49 Unperturbedmateri_l response 97 50 Nominal heating rate profile 104 .I 5] Land length error evaluation log 52 Thermocouple land length analysis summary III _i i Ix / 00000002-TSA09 LIST OF ILLUSTRATIONS(CDncludod) .,r b 53 RCC testinstrumentation 112 54 Test heat slnk rosponso 115 i 5B SlmpliflOdcalorlmeterlleatsinkanalysls 11G 56a Typicalincidentfluxmeasurementfor' InstalledGardorg_age (Test 2430, SampleNo. 8, Cycle 3) 117 56b Heatsinktlle_alresponse(Test2431,Cycle4, Sample8) 118 I J i X '_' 00000002-TSA10 ',! I f } |, LIST OF TABLE5 1 HRSIcoating thormophysical proporties _4 I HRS!thOrmophystcal proportto_ _5 ! 3 Calarlmetorovaluation R7 I 4 HRS!thermocouplocomparison 46 _ ! 5 VO_yhightemperature_heathmatol'lals 50 6 Testconditions 89 7 HRSltestsampledescription 99 8 Testsummary I00 ! 9 Summaryof screeningtestresults lOl ! 1 I0 Test sampledescription 105 ! II Uncertaintyin correlationof heatfluxwith _urface temperature(at 1256K) I0_ 12 RCC dataanalysis If3 ° 1 xi 00000002-TSA11 SECTIONI SUMMARY _.J'Iththe.development _f advanced reusable,heat _hleld matorlals for _l_i_(:(_ _hutt]e application, it became apparent that existing instrumentationused for l,rU- vious thermal protectionsystems was not adequate for the requirementsof a shuttl(, vehicle which was being designed for a minimum lO0 mission life time capahllIty. Existing instrumentationhad been developed primarily for use in reentry heaL shi,,Id_, on spacecraftsuch as Mercury and Apollo with no reuse requirement. The *ma,;,'.h,,_. tle Orbiter, however,must survive a multip]e number of reentries withmat slnnlfic,ml change in the characteristicsof the heat shield materials. The cuncept of _,fully reusable thermal protectionsystem established the need for advanced instrumont.,_ti(m to (1) be used in the developmentand qualificationof the heat shield and (2) t(_ monitor the performanceof the heat shield system during operationa] flights, The, stringent requirements for the shuttle applicationmade it clear that addltiom_ld(_- velopmentwas required. This program was initiated to address those problems. The primary objective of this program was to develop and determine the adequ,,- cy of thermal and flow sensor instrumentationwhich are an integral part of the (_rbi- ter reusable TPS. The ultimate objective of the effort was to recommend to NASA the type of sensors to be used, the installationprocedure,and the accuracy of the measurements expected for the orbiter TPS instrumentation. The program consisted of three basic tasks: e Task I - InstrumentationInstallatlonStudy 0 Task 2 - Testing i ii Task 3 - Data Reduction and Analyses

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