High-Temperature, MHz-Bandwidth, Miniaturized Heat-Flux Sensors for High-Speed Flows

The Interdisciplinary Consulting Corporation (IC2) proposes to develop high-temperature, high-bandwidth, miniaturized heat flux sensors that are applicable in a variety of environmental conditions such as those encountered in high-speed ground- and flight-test facilities. The proposed sensing system addresses a critically unmet measurement need in NASAs technology portfolio, specifically the ability to make quantitative, time-resolved, mean and fluctuating heat-flux measurements with sufficient dynamic range, bandwidth, and spatial resolution in high-temperature, high-speed flows using a robust, miniature sensor to facilitate installation in scale models and high-speed ground- and flight-test facilities. The sensor system will enable single-point measurement of heat flux for characterization of complex boundary layer flows in ground-test facilities over a wide range of temperatures, with a target maximum continuous operating temperature 1000 K (727 C). The proposed heat-flux sensor consists of a microfabricated thin-film thermopile on top of a support substrate with a thin protective coating and backside electrical connections. This design represents a robust, flush-mounted, miniature, heat-flux sensing system that possesses improved sensor survivability, reduced humidity sensitivity, and less bulky, fragile packaging than existing solutions. The flow disturbance for this sensor is minimal because of the flush-mount design and small footprint. Optimized sensor electronics will also help improve the sensitivity, dynamic range, and bandwidth of the sensor. The Interdisciplinary Consulting Corporation (IC2) proposes to develop high-temperature, high-bandwidth, miniaturized heat flux sensors that are applicable in a variety of environmental conditions such as those encountered in high-speed ground- and flight-test facilities. The sensor system will enable single-point measurement of heat flux for characterization of complex boundary layer flows in ground-test facilities over a wide range of temperatures, with a target maximum continuous operating temperature >1000 K (727 °C). The proposed heat-flux sensor consists of a microfabricated thin-film thermopile on top of a support substrate with a thin protective coating and backside electrical connections. This design represents a robust, flush-mounted, miniature, heat-flux sensing system that possesses improved sensor survivability over existing solutions. The flow disturbance for this sensor is minimal because of the flush-mount design and small footprint. Optimized sensor electronics will also help improve the sensitivity, dynamic range, and bandwidth of the sensor. The following technical objectives have been established to meet the Phase II goals: Complete a review of the requirements for the heat flux sensor system that were developed in Phase I and update the requirements based on new information Update the conceptual design for the sensor, packaging, electronics, and calibration setup Design and fabricate optimized heat flux sensors Design/build/test revised electronics designs to improve performance and achieve the desired form factor Assemble and characterize an updated laser diode calibration setup for static and dynamic sensor calibration Develop a prototype package design and assembly process to achieve the target operating temperature Characterize the sensor system, including static and dynamic calibration, over the target operational temperature range The proposed deliverables for the Phase II effort include: Required contract deliverables (Initial Summary Chart, IT Security Management Plan, Quarterly Demonstration Reports, New Technology Report(s), Interim and Final New Technology Summary Reports (NTSRs), Final Technical Report, Final Summary Chart) Interim and final Technical and Business Assistance (TABA) reports

Potential applications for the system include use within NASA’s supersonic and hypersonic ground-test facilities such as the 20-inch Mach 6 Air Tunnel, 31-inch Mach 10 Air Tunnel, and the 8-Foot High Temperature Tunnel (8-ft HTT) at NASA Langley Research Center (LaRC) as well as other high-speed facilities at NASA’s Glenn and Ames Research Centers. This technology is also applicable to DOD high-speed test facilities, e.g., Tunnel A/B/C at AEDC and Tunnel 9 at AEDC White Oak, as well as commercial defense contractors working in the guided missile and space vehicle manufacturing (e.g., Boeing Defense, Lockheed Martin, Raytheon).

This is early/mid-stage (TRL 3) — the most realistic path in is NASA SBIR/STTR, which funds small businesses and research institutions to develop technology aligned with NASA's needs (equity-free, phased funding). Check whether a current SBIR/STTR solicitation topic overlaps with this project's technology area, or contact the project directly (above) to ask.

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