This research produced a new class of skin friction gages that measures wall shear even in shock environments. One test specimen separately measured wall shear and variable-pressure induced moment. Through the investigation of available computational modeling methods, techniques for accurately predicting gage physical responses were developed. The culmination of these model combinations was a design optimization procedure. This procedure was applied to three disparate test conditions: 1) short-duration, high-enthalpy testing, 2) blow-down testing, and 3) flight testing. The resulting optimized gage designs were virtually tested against each set of nominal load conditions. The finalized designs each successfully met their respective test condition constraints while maximizing strain output due to wall shear. These gages limit sources of apparent strain: inertia, temperature gradient, and uniform pressure. A unique use of bellows provided a protective shroud for surface strain gages. Oil fill provided thermal and dynamic damping while eliminating uniform pressure as a source of output voltage. Two Wheatstone bridge configurations were developed to minimize temperature effects first from temperature gradient and then from spatially varying heat flux induced gradient. An inertia limiting technique was developed that parametrically investigated mass and center of gravity impact on strain output. Multiple disciplinary computational simulations of thermal, dynamic, shear, moment, inertia, and instrumentation interaction were developed. Examinations of instrumentation error, settling time, filtering, multiple input dynamic response, and strain gage placement to avoid thermal gradient were conducted. Detailed mechanical drawings for several gages were produced for fabrication and future testing. / Ph. D.

This study concerns the design, analysis, and initial testing of a novel skin friction gage for applications in three-dimensional, high-speed, high-enthalpy flows. Design conditions required favorable gage performance in the Arc-Heated Facilities at Arnold Engineering Development Center. Flow conditions are expected to be at Mach 3.4, with convective heat properties of h= 1,500 W/(m°·K) (264 Btu/(hr·ft°·°R)) and T_aw= 3,900 K (7,000 °R). The wall shear stress is expected to be as high as τ_w= 2,750 Pa (0.40 psi) with a correlating coefficient of skin friction value around C_f= 0.0035. Through finite element model and analytical analyses, a generic gage design is predicted to remain fully functional and within reasonable factors of safety for short duration tests. The deflection of the sensing head does not exceed 0.025 mm (0.0001 in). Surfaces exposed to the flow reach a maximum temperatures of 960 K (1,720 °R) and the region near the sensitive electronic components experience a negligible rise in temperature after a one second test run. The gage is a direct-measuring, non-nulling design in a cantilever beam arrangement. The sensing head is flush with the surrounding surface of the wall and is separated by a small gap, approximately 0.127 mm (0.005 in). A dual-axis, semi-conductor strain gage unit measures the strain in the beam resulting from the shear stress experienced by the head due to the flow. The gage design incorporates a unique bellows system as a shroud to contain the oil filling and protect the strain gages. Oil filling provides dynamic and thermal damping while eliminating uniform pressure loading. An active water-cooling system is routed externally around the housing in order to control the temperature of the gage system and electronic components. Each gage is wired in a full-bridge Wheatstone configuration and is calibrated for temperature compensation to minimize temperature effects. Design verification was conducted in the Virginia Tech Hypersonic Tunnel. The gage was tested in well-documented Mach 3.0, cold and hot flow environments. The tunnel provided stagnation temperatures and pressures of up to T₀= 655 K (1,180 °R) and P₀= 1,020 kPa (148 psi) respectively. The local wall temperatures ranged from T_w= 292 to 320 K (525 to 576 °R). The skin friction coefficient measurements were between 0.00118 and 0.00134 with an uncertainty of less than 5%. Results were shown to be repeatable and in good concurrence with analytical predictions. The design concept of the gage proved to be very sound in heated, supersonic flow. When it worked, it did so very effectively. Unfortunately, the implementation of the concept is still not robust enough for routine use. The strain gage units in general were often unstable and proved to be insufficiently reliable. The detailed gage design as built was subject to many potential sources of assembly misalignment and machining tolerances, and was susceptible to pre-loading. Further recommendations are provided for a better implementation of this design concept to make a fully functional gage test ready for Arnold Engineering Development Center. / Master of Science