Measurement of local high-level, transient surface heat flux

This study is part of a continuing investigation to develop methods for measuring local transient surface heat flux. A method is presented for simultaneous measurements of dual heat fluxes at a surface location by considering the heat flux as a separate function of heat stored and heat conducted within a heat flux gage. Surface heat flux information is obtained from transient temperature measurements taken at points within the gage. Heat flux was determined over a range of 4 to 22 MW/sq m. It was concluded that the method is feasible. Possible applications are for heat flux measurements on the turbine blade surfaces of space shuttle main engine turbopumps and on the component surfaces of rocket and advanced gas turbine engines and for testing sensors in heat flux gage calibrators

Heat flux calibration facility capable of SSME conditions

There is a need to more thoroughly characterize the hostile space shuttle main engine (SSME) turbopump environment. It has been estimated that component surface heat flux in the hot-gas environment is about 10 MW/square meter, and this is about 50 times that encountered in aircraft engines. Also, material temperature transients can be as high as 1000 K in about 1 second. These transients can cause durability problems such as material cracking. Heat flux sensors placed in the turbopump components can partially characterize this environment by measuring surface heat flux. These heat flux data can be used to verify analytical-stress, boundary-layer, and heat-transfer design models. Preliminary plans were discussed at the first SSME durablity conference for designing and fabricating a new facility for the calibration and durability testing of prototype heat flux sensors for the SSME. This facility, which is necessary for assessment of new heat flux gauge concepts needed in the hostile SSME turbopump environment, is described

Calibrator tests of heat flux gauges mounted in SSME blades

Measurements of heat flux to space shuttle main engine (SSME) turbine blade surfaces are being made in the Lewis heat flux calibration facility. Surface heat flux information is obtained from transient temperature measurements taken at points within the gauge. A 100-kW Vortek arc lamp is used as a source of thermal radiant energy. Thermoplugs, with diameters of about 0.190 cm and lengths varying from about 0.190 to 0.320 cm, are being investigated. The thermoplug is surrounded on all surfaces except the active surface by a pocket of air located in the circular annulus and under the back cover. Since the thermoplug is insulated, it is assumed that heat is conducted in a one-dimensional manner from the hot active surface to the cooler back side of the thermoplug. It is concluded that the miniature plug-type gauge concept is feasible for measurement of blade surface heat flux. It is suggested that it is important to measure heat flux near the hub on the suction surface and at the throat on SSME blades rotating in engines because stress and heat transfer coefficients are high in this region

Progress in the measurement of SSME turbine heat flux with plug-type sensors

Data reduction was completed for tests of plug-type heat flux sensors (gauges) in a turbine blade thermal cycling tester (TBT) that is located at NASA/Marshall Space Flight Center, and a typical gauge is illustrated. This is the first time that heat flux has been measured in a Space Shuttle Main Engine (SSME) Turbopump Turbine environment. The development of the concept for the gauge was performed in a heat flux measurement facility at Lewis. In this facility, transient and steady state absorbed surface heat flux information was obtained from transient temperature measurements taken at points within the gauge. A schematic of the TBT is presented, and plots of the absorbed surface heat flux measured on the three blades tested in the TBT are presented. High quality heat flux values were measured on all three blades. The experiments demonstrated that reliable and durable gauges can be repeatedly fabricated into the airfoils. The experiment heat flux data are being used for verification of SSME analytical stress, boundary layer, and heat transfer design models. Other experimental results and future plans are also presented

Miniature high temperature plug-type heat flux gauges

The objective is to describe continuing efforts to develop methods for measuring surface heat flux, gauge active surface temperature, and heat transfer coefficient quantities. The methodology involves inventing a procedure for fabricating improved plug-type heat flux gauges and also for formulating inverse heat conduction models and calculation procedures. These models and procedures are required for making indirect measurements of these quantities from direct temperature measurements at gauge interior locations. Measurements of these quantities were made in a turbine blade thermal cycling tester (TBT) located at MSFC. The TBT partially simulates the turbopump turbine environment in the Space Shuttle Main Engine. After the TBT test, experiments were performed in an arc lamp to analyze gauge quality

Method of producing a plug-type heat flux gauge

A method of making a plug-type heat flux gauge in a material specimen in which a thermoplug is integrally formed in the specimen is disclosed. The thermoplug and concentric annulus are formed in the material specimen by electrical discharge machining and trepanning procedures. The thermoplug is surrounded by a concentric annulus through which thermocouple wires are routed. The end of each thermocouple wire is welded to the thermoplug, with each thermocouple wire welded at a different location along the length of the thermoplug

Plug-type heat flux gauge

A plug-type heat flux gauge formed in a material specimen and having a thermoplug integrally formed in the material specimen, and a method for making the same are disclosed. The thermoplug is surrounded by a concentric annulus, through which thermocouple wires are routed. The end of each thermocouple wire is welded to the thermoplug, with each thermocouple wire welded at a different location along the length of the thermoplug. The thermoplug and concentric annulus may be formed in the material specimen by electrical discharge machining and trepanning procedures

Heat flux measurements

A new automated, computer controlled heat flux measurement facility is described. Continuous transient and steady-state surface heat flux values varying from about 0.3 to 6 MW/sq m over a temperature range of 100 to 1200 K can be obtained in the facility. An application of this facility is the development of heat flux gauges for continuous fast transient surface heat flux measurement on turbine blades operating in space shuttle main engine turbopumps. The facility is useful for durability testing at fast temperature transients

Miniature Convection Cooled Plug-type Heat Flux Gauges

Tests and analysis of a new miniature plug-type heat flux gauge configuration are described. This gauge can simultaneously measure heat flux on two opposed active surfaces when heat flux levels are equal to or greater than about 0.2 MW/m(sup 2). The performance of this dual active surface gauge was investigated over a wide transient and steady heat flux and temperature range. The tests were performed by radiatively heating the front surface with an argon arc lamp while the back surface was convection cooled with air. Accuracy is about +20 percent. The gauge is responsive to fast heat flux transients and is designed to withstand the high temperature (1300 K), high pressure (15 MPa), erosive and corrosive environments in modern engines. This gauge can be used to measure heat flux on the surfaces of internally cooled apparatus such as turbine blades and combustors used in jet propulsion systems and on the surfaces of hypersonic vehicles. Heat flux measurement accuracy is not compromised when design considerations call for various size gauges to be fabricated into alloys of various shapes and properties. Significant gauge temperature reductions (120 K), which can lead to potential gauge durability improvement, were obtained when the gauges were air-cooled by forced convection

An Investigation of the Compatibility of Radiation and Convection Heat Flux Measurements

A method for determining time-resolved absorbed surface heat flux and surface temperature in radiation and convection environments is described. The method is useful for verification of aerodynamic, heat transfer and durability models. A practical heat flux gage fabrication procedure and a simple one-dimensional inverse heat conduction model and calculation procedure are incorporated in this method. The model provides an estimate of the temperature and heat flux gradient in the direction of heat transfer through the gage. This paper discusses several successful time-resolved tests of this method in hostile convective heating and cooling environments