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

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

Emittance and absorptance of NASA ceramic thermal barrier coating system

Spectral emittance measurements were made on a two-layer ceramic thermal barrier coating system consisting of a metal substrate, a NiCrAly bond coating and a yttria-stabilized zirconia ceramic coating. Spectral emittance data were obtained for the coating system at temperatures of 300 to 1590 K, ceramic thickness of zero to 0.076 centimeter, and wavelengths of 0.4 to 14.6 micrometers. The data were transformed into total hemispherical emittance values and correlated with respect to ceramic coating thickness and temperature using multiple regression curve fitting techniques. The results show that the ceramic thermal barrier coating system is highly reflective and significantly reduces radiation heat loads on cooled gas turbine engine components. Calculation of the radiant heat transfer within the nonisothermal, translucent ceramic coating material shows that the gas-side ceramic coating surface temperature can be used in heat transfer analysis of radiation heat loads on the coating system

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

Heat-transfer experiments on a 34-ampere-hour nickel-cadmium cell

measurement of temperature distribution in operating nickel-cadmium electric batterie

Ceramic thermal protective coating withstands hostile environment of rotating turbine blades

Ceramic coatings have low thermal conductivity. They provide potential for increased engine performance, reduced fuel consumption, use of less costly materials or construction procedures, and increased life and durability

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

A method for measuring cooling air flow in base coolant passages of rotating turbine blades

Method accurately determines actual coolant mass flow rate in cooling passages of rotating turbine blades. Total and static pressures are measured in blade base coolant passages. Mass flow rates are calculated from these measurements of pressure, measured temperature and known area

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