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Commercial Upgraded Military Heritage Re-entry Vehicle Thermal Sensors

Commercial Upgraded Military Heritage Re-entry Vehicle Thermal Sensors for Current Generation TPS Material Ground & Flight Test Evaluation Paper/Presentation to the Thermal & Fluids Analysis Workshop (TFAWS) 2004 Pasadena California, Paper no. 109-A0027 August 30 through September 3, 2004

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Commercial Upgraded Military Heritage Re-entry Vehicle Thermal Sensors

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  1. Commercial Upgraded Military Heritage Re-entry Vehicle Thermal Sensors for Current Generation TPS Material Ground & Flight Test Evaluation Paper/Presentation to the Thermal &FluidsAnalysisWorkshop(TFAWS) 2004 Pasadena California, Paper no. 109-A0027 August 30 through September 3, 2004 John M. Cassanto, President & CEO George D’Heilly, KSC Manager Ted Moller, Manager Phil Ritchie. Consultant Roger Wayne, Specialist 108 Ashland Drive Downingtown, PA 19335 Tel: (610) 280 0869, (610) 363 7971 Cell: 484 431 5028 Fax: (610) 524 1988 Email: AstrometricsJMC@aol.com

  2. OVERVIEW/SUMMARY 1. FLIGHT TEST INSTRUMENTATION WERE DEVELOPED IN THE 70’s FOR DOD RE-ENTRY VEHICLES TO EVALUATE HEATSHIELD/TPS PERFORMANCE 2. TPS SENSORS WERE SPUN OFF AS A COMMERCIAL ENDEAVOR IN THE MID 80’s AND HAVE BEEN AVAILABLE FOR MORE THAN 20 YEARS 3. THE SENSORS HAVE BEEN CONTINUOUSLY UPGRADED AND SUBJECTED TO FULL SCALE FLIGHT TESTS (TRL 6) TO MEET CLIENT REQUIREMENTS -INCREASED SENSITIVITY -SMALLER FOOTPRINT -TAILORED TO SPECIFIC TPS MATERIAL -HIGHER OPERATING TEMPERATURES 4. TPS INSTRUMENTATION HAS FOCUSED ON - HEATFLUX/TRANSITION SENSORS - ABLATION/RECESSION SENSORS - MULTI-ELEMENT THERMOCOUPLE PLUGS - ACCURATE DUAL RANGE PRESSURE SENSORS 5. UPGRADED COMMERICAL TPS SENSORS WITH A MILITARY HERATIGE & TRACK RECORD CAN BE USED FOR CURRENT NASA AND DOD FLIGHT & GROUND TEST EVALUATION OF ADVANCED TPS ABLATIVE MATERIALS

  3. AGENDA • 1. R/V TPS INSTRUMENTATION: DOD HERATIGE • . 2. HEAT FLUX/TRANSITION MEASUREMENTS: DELTA-T SENSOR • . 3. ABLATION MEASUREMENTS: ARAD SENSOR • .4. ISOTHERMAL MEASUREMENTS: 4 ELEMENT EMBEDDED T/C PLUG • .5. FLIGHT TEST DATA: UNIQUE EXAMPLES • 6.SENSOR/UPGRADES • 7. CONCLUSIONS/RECOMMENDATIONS

  4. TYPICAL FLIGHT TEST THERMAL INSTRUMENTATION REQUIRED TO EVALUATE TPS MATERIALS

  5. DOD Aerospace “Off-the-Shelf” Heat Shield Instrumentation

  6. Flight Heritage of Delta-T, ARAD, & Embedded Plug Multi-Element Thermocouple Sensors • Air Force: Minuteman MK-12, 12A, PVM, STV, RVAP, ABRES, MTV, RVTO-1, RVTA-3B, Carbon-Carbon Nose Tip Flights, LBRV Recovered Vehicle • NASA: GALILEO Jupiter Entry Probe flew Commercial ARAD Sensors. Heatshield survived to lower altitudes than predicted based on ARAD telemetry data.

  7. DELTA-T HEATFLUX/TRANSITION GAGE FLIGHT DATA • Q - Heating Rate • Onset of Transition from Laminar to Turbulent • Transition Front Mapping & Asymmetries • Aggravated Heating Data: Potential for TPS Gouging

  8. Delta-T Heat Flux/Transition Gage PHOTO SCHEMATIC

  9. Examples of Precision Laser Welding of Delta-T

  10. Delta-T Raw Telemetry Flight Test Data

  11. THE DELTA-T GAGE HAS A TIME RESPOSE IN MILISECONDS COMPARABLE TO A BLAM ACCOUSTIC GAGE BLAM ACCOUSTIC SENSOR RAW FLIGHT DATA DELTA-T HEAT FLUX & TRANSITION SENSOR RAW FLIGHT DATA

  12. The Miniaturized Delta-T Transition Gage has a Low Inboard Profile

  13. Samples of the Standard & Double Delta-T DOUBLE DELTA-T SENSOR BUILT TO LOCKHEED MARTIN REQUIREMENTS FOR DUAL RANGE & INCREASED SENSITIVITY PERFORMANCE STANDARD DELTA-T SENSOR

  14. DELTA-T TELEMETRY DATA CAN DETERMINE THE PRESENSE OF HIGH ALTITUDE TURBULENT WEDGES AFT OF ANTENNA WINDOWS PRIOR TO ONSET OF R/V TRANSITION LAMINAR FLOW AT T~1.5 SEC LAMINAR FLOW AT T~1.5 SEC TURBULENT FLOW AT T~1.5 SEC TURBULENT FLOW AT T~1.5 SEC TURBULENT FLOW WEDGE MAP RAW DELTA-T TELEMETRY DATA

  15. Transition Mapping & High Altitude Turbulent Wedges From Delta-T Gage R/V Flight Test Data Boundary Layer Transition Map Turbulent Wedge Definition

  16. TURBULENT WEDGES FORM IN R/V LAMINAR FLOW AFT OF ANTENNA WINDOWS BASED ON FLIGHT TEST DATA FLIGHT DATA FROM RECOVERED R/V & ARAD SENSOR TELEMETRY SHOWING AGRAVATED HEATING AND RECESSION AFT OF ANTENNA WINDOWS TURBULENT WEDGES AFT OF ANTENNA WINDOWS MEASURED FROM DELTA-T SENSOR TELEMETRY DATA

  17. ARAD (ANALOG RESISTANCE ABLATION DETECTOR) GAGE FLIGHT DATA • Ablation/Recession History of TPS • Defines Char Layer-Virgin Heat Shield I/F • Monitors TPS Degradation Isotherm • Defines HS Margin Vs Altitude via Telemetry • Aggravated Heating/Gouging in Critical Zones

  18. Schematic Showing ARAD Recession/Char layer Sensor for Flight & Ground TPS Evaluation ARAD SENSOR REFERENCE: “ A SIMPLE RECESSION GAGE FOR INFLIGHT MEASUREMENT OF THE CHAR DEGRADATION ZONE FOR RE-ENTRY VEHCILE HEATSHIELDS” ISA PAPER BY J. M. CASSANTO ET AL ., 26TH INTERNATIONAL INSTRUMENTATION SYMPOSIUM, SEATTLE, MAY 5-8, 1980

  19. Raw ARAD Telemetry Recession Flight Data

  20. LBRV-1 ARAD Recession Data Compared with Previous Flight Data

  21. Comparison of ARAD Flight Recession Data with Predictions

  22. ARAD HEATSHIELD ABLATION FLIGHT DATA AND CHAR LAYER CORRELATION

  23. Galileo Jupiter Probe Used ARAD Sensors to Determine Recession History & Ablated Shape • Jupiter Probe TPS Experienced Severe Conditions • Mach No ~50, Velocity ~47 Km/sec • Re-entry Loads ~ 250 g’s • Peak Heating Rate ~ 30kW/cm, 300kJ/cm • ARAD Sensors Provided by GE for the Jupiter Probe Obtained Good Data and Met Mission Requirements • GE is no Longer in the Flight Sensor Business • ARAD Sensors Provided to NASA for the Jupiter Probe were Fabricated by GE/Astrometrics Personnel. Jupiter Probe ARAD Design Has been Upgraded and has been Available “Off the Shelf” Commercially Since the 1980’s. F

  24. Galileo Jupiter Probe Used ARAD Sensors to Determine Recession History & Ablated Shape • Jupiter Probe TPS Experienced Severe Conditions • Mach No ~50, Velocity ~47 Km/sec • Re-entry Loads ~ 250 g’s • Peak Heating Rate ~ 30kW/cm, 300kJ/cm • ARAD Sensors Provided by GE for the Jupiter Probe Obtained Good Data and Met Mission Requirements • GE is no Longer in the Flight Sensor Business • ARAD Sensors Provided to NASA for the Jupiter Probe were Fabricated by GE/Astrometrics Personnel. Jupiter Probe ARAD Design Has been Upgraded and has been Available “Off the Shelf” Commercially Since the 1980’s. F

  25. ARAD TPS Ablation Data From NASA Jupiter Probe Typical ARAD Sensor for Jupiter Probe Fabricated by GE/Astrometrics Personnel. Figure From Ed Martinez Presentation titled “Thermal Microsensor development” NASA Ames Research Center, August 23, 2003 ARAD Recession Data from Jupiter Probe Jupiter Probe Configuration with ARAD Locations

  26. ARAD Flight Test Recession Data on Quartz Phenolic Nose Tip

  27. Matrix of ARAD* Sensors Flown on Various Heat Shield Materials * All ARAD Sensors were Fabricated by GE/Astrometrics Personnel

  28. Thermal Arc Ground Data Comparison of a Single ARAD Sensor with Two Discrete Thermocouple Plug Data Points (1300 deg Isotherm) Two Plug Thermocouples at Two Discrete Data Points in time One ARAD Sensor, Continuous Data

  29. Flight Comparison of a Single ARAD Sensor with Multiple Plug Thermocouples at Different Depths One ARAD Sensor, Continuous Data Throughout Re-entry , 1 TM Channel, 1 Checkout/Sensor Stem Test Four Plug TC’s Single ARAD 4 Discrete Single 1300 F Thermocouple Data Pts, 4 TM Chs, 4 Checkout/ Sensor Stem Tests

  30. BASIC REFERENCE FOR THE ARAD ABLATION GAGE

  31. QUAD MULTI-ELEMENT EMBEDDED THERMOCOUPLE PLUG

  32. MULTI-ELEMENT QUAD EMBEDDED PLUG THERMOUCOUPLE PHOTO OF FOUR EMEMENT PLUG THERMOCOUPLE SCHEMATIC OF FOUR ELEMENT PLUG THERMOCOUPLE TYPICAL FLIGHT DATA FROM MULTI-ELEMENT EMBEDDED PLUG THERMOCOUPLE

  33. Capability/Status of Existing Delta-T, ARAD, & Multi-Element Thermocouple Plug Sensors • Delta-T: Operates at temperatures in the range of 2150 Deg F. Range can be extended to 3150 Deg F if required. • ARAD: Operates in 1300 to 3500 Deg F isotherm. Range can be extended. • Quad: Embedded Plug T/C’s current temperature range is 2500 to 4000 Deg F. • Dual Range Extender for Pressure Sensors:Electronics prototype needs to proceed to flight hardware status

  34. Concluding Remarks (TPS Validation) • Flight Test Data is Essential & Real World. • Use of Reliable Sensors with a Flight Heritage is Cost Effective for both ground & Flight tests. • Existing Upgraded “Off the Shelf” Military Heritage Commercial Sensors operate in the 2500 to 4000 Deg F range and are Applicable for NASA Planetary Probes and DOD Ballistic & Maneuvering Glide Vehicles. • Commercial Sensors can be Further Upgraded to Include Higher Temperature Capability & Tailored to new TPS Requirements/Characteristics if Needed. • The Commercial TPS Sensors Described in this Paper will be Tested in a Silica Phenolic Heat Shield at the Langley Thermal Arc 4th quarter 2004.

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