Due to the Columbia Space Shuttle Accident of February 2003, the Columbia Accident Investigation Board determined the need for an on-orbit inspection system for the Thermal Protection System that accurately determines damage depth to 0.25". NASA contracted the Spacecraft Technology Center in College Station, Texas, for a proof-of-concept photogrammetric system. This system involves a high quality digital camera placed on the International Space Station, capable of taking high fidelity images of the orbiter as it rotates through the Rendezvous Pitch Maneuver. Due to the pitch rotation, the images are tilted at different angles. The tilt causes the damage to exhibit parallax between multiple images. The tilted images are therefore registered to the near-vertical images using visually striking features on the undamaged surface of the Thermal Protection System that appear in multiple images taken at different tilt angles. The images become relatively oriented after registration, and features in one image are ensured to lie on the epipolar line in the other images. Features that do not lie on the undamaged surface, however, are shifted in the tilted images. These pixels are matched to the near-vertical image using a sliding-window area-matching approach. The windows are matched using a least-squares error method. The change in location for a pixel in a tilted image from its expected location on the undamaged surface is called the pixel disparity. This disparity is linearly scaled using the tilt angle and the pixel sampling to determine the depth of the damage at that pixel location. The algorithm is tested on a set of damaged tiles at the Johnson Space Center in Houston and the photogrammetric damage depth is then compared to a set of truth data provided by NASA. The photogrammetric method shows promise, with the 0.25" error limit being exceeded in only a few pixel locations. Once the camera properties are fully known from calibration, this systematic error should be reduced.

This thesis presents the derivation of the theory leading to the determination of the governing equations of chemically reacting flows under local thermodynamic equilibrium, which rigorously takes into account effects of elemental (de)mixing. As a result, new transport coefficients appear in the equations allowing a quantitative predictions and helping to gain deeper insight into the physics of chemically reacting flows at and near local equilibrium. These transport coefficients have been computed for both air and carbon dioxide mixtures allowing the application of this theory to both Earth and Mars entry problems in the framework of the methodology for the determination of the catalytic activity of Thermal Protections Systems (TPS) materials. Firstly, we analyze the influence of elemental fraction variations on the computation of thermochemical equilibrium flows for both air and carbon dioxide mixtures. To this end, the equilibrium computations are compared with several chemical regimes to better analyze the influence of chemistry on wall heat flux and to observe the elemental fractions behavior along a stagnation line. The results of several computations are presented to highlight the effects of elemental demixing on the stagnation point heat flux and chemical equilibrium composition for air and carbon dioxide mixtures. Moreover, in the chemical nonequilibrium computations, the characteristic time of chemistry is artificially decreased and in the limit the chemical equilibrium regime, with variable elemental fractions, is achieved. Then, we apply the closed form of the equations governing the behavior of local thermodynamic equilibrium flows, accounting for the variation in local elemental concentrations in a rigorous manner, to simulate heat and mass transfer in CO2/N2 mixtures. This allows for the analysis of the boundary layer near the stagnation point of a hypersonic vehicle entering the true Martian atmosphere. The results obtained using this formulation are compared with those obtained using a previous form of the equations where the diffusive fluxes of elements are computed as a linear combination of the species diffusive fluxes. This not only validates the new formulation but also highlights its advantages with respect to the previous one : by using and analyzing the full set of equilibrium transport coefficients we arrive at a deep understanding of the mass and heat transfer for a CO2/N2 mixture. Secondly, we present and analyze detailed numerical simulations of high-pressure inductively coupled air plasma flows both in the torch and in the test chamber using two different mathematical formulations: an extended chemical non-equilibrium formalism including finite rate chemistry and a form of the equations valid in the limit of local thermodynamic equilibrium and accounting for the demixing of chemical elements. Simulations at various operating pressures indicate that significant demixing of oxygen and nitrogen occurs, regardless of the degree of nonequilibrium in the plasma. As the operating pressure is increased, chemistry becomes increasingly fast and the nonequilibrium results correctly approach the results obtained assuming local thermodynamic equilibrium, supporting the validity of the proposed local equilibrium formulation. A similar analysis is conducted for CO2 plasma flows, showing the importance of elemental diffusion on the plasma behavior in the VKI plasmatron torch. Thirdly, the extension of numerical tools developed at the von Karman Institute, required within the methodology for the determination of catalycity properties for thermal protection system materials, has been completed for CO2 flows. Non equilibrium stagnation line computations have been performed for several outer edge conditions in order to analyze the influence of the chemical models for bulk reactions. Moreover, wall surface reactions have been examined, and the importance of several recombination processes has been discussed. This analysis has revealed the limits of the model currently used, leading to the proposal of an alternative approach for the description of the flow-surface interaction. Finally the effects of outer edge elemental fractions on the heat flux map is analyzed, showing the need to add them to the list of parameters of the methodology currently used to determine catalycity properties of thermal protection materials.

Inductively Coupled Plasma (ICP) facilities create high enthalpy ows to recreate atmospheric entry conditions. Although no condition has been duplicated exactly in a ground test facility, it is important to characterize the condition to understand how close a facility can come to doing so. An ICP facility was constructed at the University of Vermont for aerospace material testing in 2010. The current setup can operate using air, carbon dioxide, nitrogen, and argon to test samples in a chamber. In this work we investigate di erent ways to increase measured heat ux and expand our facility to operate supersonically. To do so, a water cooled injection system was designed to overcome failure points of the prior system. An investigation of heat ux methods that provide a baseline for the facility were also examined and tested. A nozzle con guration was also developed with an overall goal of increasing the plasma ow to reach sonic and supersonic velocities, allowing it to be compared with the existing subsonic system. An iterative approach was taken to develop a nozzle design that is robust enough to handle the harsh environment, yet adaptable to the pre-existing facility components. The current design uses interchangeable sonic and supersonic nozzles which also allow for appropriate plasma gas expansion. Data are taken through retractable and goose-neck probe sample holders during testing. Heat ux can be determined by use of a Gardon gage, slug calorimeter, and water cooled calorimeter. Total and static pressure are determined from a pitot tube and pressure tap, which are then manipulated into a velocity measurement. A comparison between subsonic and supersonic operation is then made with these data. Existing literature uses correlations between jet diameter and velocity gradients to determine the e ective heat ux. This investigation found that the experimental and theoretical heat ux results scale correctly according to the correlations.

Metallic honeycomb structures are being studied for use as thermal protection systems for hypersonic vehicles and as structural panels in other aerospace applications. One potential concern is the growth of fatigue cracks in the thin face-sheets used for these structures. To address this concern, the fatigue behavior of thin aluminum base alloy sheets ranging from 30 m to 250 m in thickness was investigated. The effect of material roll direction was also considered at 30 m. In all cases, the fatigue crack growth rates were found to be one to two orders of magnitude higher than that of the same material of greater thickness. In addition to data for fatigue crack growth rate, data are also presented for the effect of thickness on the fracture toughness of these materials.

The research conducted at the department of Electrical Engineering of the University of South Florida campus in Tampa only covers the electrical aspect of electric drives. However, the performance of electric machinery is significantly impacted by temperature variation. The literature review shows three main control techniques in use today in electric drives namely, Scalar control, Direct Torque control and Field Oriented control. This thesis presents a temperature rise of rotor bars, stator winding, stator core and stator frame in a running three phase field-oriented controlled induction machine. A literature search shows that none of research has been carried out to investigate a thermal response of a field-oriented controlled induction motor. With this motivation, we were able to implement a lumped parameters thermal model of a three-phase field-oriented IM in MATLAB Simulink, which allows us to determine that rotor bars have the highest temperatures rising to 84 degrees Celsius. This confirms that rotors bars are the hottest part of a running IM as stipulated in literature.

Ceramic colloidal processing routes such as slip casting, gelcasting and direct ink writing provide valuable insight into the role of interaction forces between particles, solvents, and polymeric additives in the rheology, particle packing, and strength of a ceramic green body. For difficult-to-densify ceramics such as the UHTCs, which find their place in extreme environment applications, precise control of each step of the manufacturing process is key. In this work, a fundamental study on the interaction between particles in non-aqueous slip casting is performed comparing the rheological behavior and consolidation with current models for interaction potential within a suspension. The advantages and drawbacks of such a model are discussed in relation to formulating a colloidal process for advanced ceramics such as ZrB2, and a case for a cyclohexane slip casting system resulting in low viscosity, shear-thinning behavior and green density of 64%, is made. The focus on non-aqueous colloidal processing is extended to gelcasting, involving three different sets of chemically curable polymer systems: HEMA+MBAM, TMPTA, and PEGDA. Merits of the gelcasting process including homogeneity, green strength, and processing time reduction are discussed, with the HEMA+MBAM system resulting in nearly an order of magnitude increase in green density from slip casting. Gelcast samples were also sintered to a density of 88% and capable of being processed in a variety of complex shapes with fine feature size on the mm scale. The properties examined in slip casting and gelcasting, as well as others pertaining to the setup of an extrusion-based additive manufacturing system, are carefully considered to design an ink that has been used to print ZrB2. The role of each additive as well as the solvent in creating an ink that is not only within the correct viscosity range for extrusion and shape retention, but also produces a strong and densely packed green body, is discussed. Finally, adjustment of printing parameters, and the method of using a low-cost rheology match to tune the settings of a pneumatic screw-extrusion printing setup, are explained. Each of these processes points to new and practical methods of complex shaping ZrB2 that can provide insight into processing of these challenging materials and create new avenues for their use in extreme environment applications, such as thermal protection systems in atmospheric re-entry vehicles. / Doctor of Philosophy / This work examines the use of ultra-high temperature ceramics (UHTCs), which are materials with some of the highest melting points in existence. These are an intriguing option for extreme environment applications. One such application is the protection of rockets, scramjets, and other hypersonic (speed > Mach 5) vehicles from the high temperatures experienced during flight and re-entry. In this work, the UHTC Zirconium diboride (ZrB2) is used as a reference material. For many of the same reasons UHTCs such as ZrB2 have extreme melting points, they can be difficult to manufacture, particularly in complex shapes. Like many ceramics, UHTCs are not melted and cast as metals are, but rather are processed in powder form to a compact known as a green body. The green body is placed in a high-temperature furnace at 2/3 - 3/4 of the melting point, where the powder undergoes sintering, or consolidation into a dense part. The manufacture of a green body that is versatile in its capacity to be molded into any shape, and allows for close packing of the particles in the powder compact to avoid failure-inducing flaws in the final component under intense loads, remains a challenge for UHTCs. Most UHTCs are hot pressed, where the powder alone is consolidated under intense heat and pressure, but this process offers very little complex shaping capacity or control of the uniformity of the part. In this work, three methods for green body manufacture using colloid-based routes, which all have unique capabilities and challenges, are described. The first process is slip casting, which is a centuries-old process that has been used for the manufacture of pottery, whitewares, and art ceramics. When used effectively, slip casting ensures that the forces between ceramic particles in a suspension, or "slip", are well-controlled such that the ceramic particles will not form clumps, or agglomerates, which create non-uniformities that weaken the final component. With information about the powder, solvent, and additives in a slip, the extent to which this will be effective can be predicted with mathematical models. This work compares the results of these models with slip casting suspensions in different solvent environments to gain knowledge about slip casting as an option for complex shaping of ZrB2. The second colloidal process discussed is gelcasting, in which the suspension of ceramic powder can undergo chemical gelation, or a reaction that transitions the suspension from a liquid to a solid, not unlike that of a natural gel such as gelatin, agarose, or albumin (egg white). The gel, which is loaded with ceramic powder, allows for more versatile shaping than slip casting, and shorter processing time; a gelcast ceramic is generally solidified in less than an hour, while a slip cast typically dries overnight. The presence the gel also provides strength to the green body, which is advantageous in handling as well as any machining to adjust the shape that may be necessary prior to sintering. The final process detailed in this work is direct ink writing, a type of additive manufacturing (or 3D printing). Knowledge gained from slip casting and gelcasting was used to carefully design a ceramic colloid that could be deposited in a layer-by-layer fashion to create a complex shape with high uniformity and control, as well as minimal surface cracking. The printed green bodies were compared in strength and sintering behavior to the gelcasts from previous chapters, and the expansion of shaping capacity for each route as it relates to aerospace applications, is described.

No description available.

Thermal systems involve multiple components assembled to store or transfer heat for power, cooling, or insulation purpose, and this research focuses on modeling the performance of two novel thermal systems that are capable of functioning in environments subjected to high heat fluxes. The first investigated thermal system is a cascaded thermoelectric generator (TEG) that directly converts heat into electricity and offers a green option for renewable energy generation. The presented cascaded TEG allows harvesting energy in high temperatures ranging from 473K to 973K, and being a solid-state device with no moving parts constitutes an excellent feature for increase device life cycle and minimum maintenance in harsh, remote environments. Two cascaded TEG designs are analyzed in this research: the two-stage and three-stage cascaded TEGs, and based on the findings, the two-stage cascaded TEG produces a power output of 42 W with an efficiency of 8.3% while the three-cascaded TEG produces 51 W with an efficiency of 10.2%. The second investigated novel thermal system is a thermal protection system inspired by the porous internal skeleton of the cuttlefish also known as cuttlebone. The presented bio- inspired thermal protection has excellent features to serve as an integrated thermal protection system for spacecraft vehicles including being lightweight (93% porosity) and possessing high compressive strength. A large amount of heat flux is generated from friction between air and spacecraft vehicle exterior, especially during reentry into the atmosphere, and part of the herein presented research involves a thermomechanical modeling analysis of the cuttlebone bio-inspired integrated thermal protection system along with comparing its performance with three conventional structures such as the wavy, the pyramid, and cylindrical pin structures. The results suggest that the cuttlebone integrated thermal protection system excels the best at resisting deformation caused by thermal expansion when subjected to aerodynamic heat fluxes. / Doctor of Philosophy / Operating engineering systems in extremely hot environments often decreases systems' reliability, life cycle, and creates premature failure. This research investigates two novel thermal systems capable of functioning in high temperatures including a cascaded thermoelectric generator (TEG) and a bio-inspired thermal protection system. The first evaluated novel thermal systems is a cascaded TEG that directly converts waste heat into power, and being a solid-state device with no moving parts forms an excellent feature for device life cycle improvement and minimum maintenance in harsh, remote environments. The research findings show that the designed cascaded TEGs can produce power when subjected to high temperatures ranging from 473K to 973K. The remaining part of the research presented in this dissertation models the thermomechanical performance of a lightweight structure, which is inspired by the internal skeleton of the cuttlefish, also knows as the cuttlebone. The cuttlefish's natural ability to support high-deep sea pressure translates into possessing high compressive strength, and when added the fact of being lightweight (up to 93% porosity), the cuttlebone forms an excellent candidate to serve as integrated thermal protection for spacecraft vehicles. The last part of the presented research discuss the thermomechanical analysis of the cuttlebone when subjected to high aerodynamics heat flux generated from friction between the air and spacecraft vehicle exterior, and it was found that the cuttlebone structure resists deformation associated with the steep temperature gradient experienced by the spacecraft vehicle during travel.

Flexible thermal protection systems are of interest due to their necessity for the success of future atmospheric entry vehicles. Current non-ablative flexible designs incorporate a two-dimensional woven fabric on the leading surface of the vehicle. The focus of this research investigation was to characterize the aerothermal performance of silicon carbide fabric using the 30 kW Inductively Coupled Plasma Torch located at the University of Vermont. Experimental results have shown that SiC fabric test coupons achieving surface temperatures between 1000°C and 1500°C formed an amorphous silicon dioxide layer within seconds after insertion into air plasmas. The transient morphological changes that occurred during oxidation caused a time dependence in the gas / surface interactions which may detrimentally affect the in-flight performance. Room temperature tensile tests of the SiC coupons have shown a rapid strength loss for durations less than 240 seconds due to oxidation. Catastrophic failure and temperature spikes were observed on almost all SiC coupons when exposed to air plasmas at heat fluxes above 80 W/cm2. Interestingly, simulation of entry into the Mars atmosphere using a carbon dioxide plasma caused a material response that was vastly different than the predictable silica layer observed during air plasma exposure.

The pyrolysis mechanics of Phenolic Impregnated Carbon Ablators (PICA) makes it a valued material for use in thermal protection systems for spacecraft atmospheric re-entry. The present study of the interaction of pyrolysis gases and char with plasma gases in the boundary layer over PICA and its substrate, FiberForm, extends previous work on this topic that has been done in the UVM 30 kW Inductively Coupled Plasma (ICP) Torch Facility. Exposure of these material samples separately to argon, nitrogen, oxygen, air, and carbon dioxide plasmas, and combinations of said test gases provides insight into the evolution of the pyrolysis gases as they react with the different environments. Measurements done to date include time-resolved absolute emission spectroscopy, location-based temperature response, flow characterization of temperature, enthalpy, and enthalpy flux, and more recently, spatially resolved and high-resolution emission spectroscopy, all of which provide measure of the characteristics of the pyrolysis chemistry and material response. Flow characterization tests construct an general knowledge of the test condition temperature, composition, and enthalpy. Tests with relatively inert argon plasmas established a baseline for the pyrolysis gases that leave the material. Key pyrolysis species such as CN Violet bands, NH, OH and Hydrogen Alpha (Hα) lines were seen with relative repeatability in temporal, spectral, and intensity values. Tests with incremental addition, and static mixtures, of reactive plasmas provided a preliminary image of how the gases interacted with atmospheric flows and other pyrolysis gases. Evidence of a temporal relationship between NH and Hα relating to nitrogen addition is seen, as well as a similar relationship between OH and Hα in oxygen based environments. Temperature analysis highlighted the reaction of the material to various flow conditions and displayed the in depth material response to argon and air/argon plasmas. The development of spatial emission analysis has been started with the hope of better resolving the previously seen pyrolysis behavior in time and space.