Thesis (Ph. D.)--California Institute of Technology, 1995. / "UMI number: 9539115"--P. [i]. Includes bibliographical references. Available on microfilm and online via the World Wide Web.

The interaction of a shock wave and boundary layer often occurs in high speed flows. For sufficiently strong shock strengths the boundary layer separates, generating shock patterns in the contiguous inviscid flow (termed strong interactions); which may also affect the performances of the systems where they occur, demanding control of the interaction to enhance the performances. The case of impinging shock wave boundary layer interaction is of fundamental importance and can throw light on the physics of the interaction in general. Although various aspects of the interaction are studied at supersonic speeds, the complexities involved in the interaction at hypersonic speeds are not well understood. Of importance is the high total enthalpy associated with hypersonic flows the simulation of which requires shock tunnels. The present experimental study focuses on the interaction between strong impinging shock and boundary layer in hypersonic flows of moderate to high total enthalpies. Experiments are performed in hypersonic shock tunnels HST-2 and FPST (free piston driven shock tunnel), at nominal Mach numbers 6 and 8, with total enthalpy ranging from 1.3 MJ/kg to 6 MJ/kg, and freestream Reynolds number ranging from 0.3 million/m to 4 million/m. The strong impinging shock is generated by a wedge of angle 30.960 to the freestream. The shock is made to impinge on a flat plate (made of Hylem which is adiabatic, except for one case with plate made of aluminium which allows heat transfer). The position of (inviscid) shock impingement may be varied (from 55 mm from the leading edge to 100 mm from the leading edge) by moving the plate back and forth on the fixture which holds the wedge and the plate. Expectedly the strong shock generates a large separation bubble of length comparable to the distance of the location of shock impingement from the leading edge of the plate. Such large separation bubbles are typical of supersonic/hypersonic intakes at off-design operation. The evolution of the flow field- including the evolution of impinging shock and subsequent evolution of the large separation bubble- within the short test duration of the shock tunnels is one of the main concerns addressed in the study. Time resolved schlieren flow visualizations using high speed camera, surface pressure measurements using PCB, kulite and MEMS sensors, surface convective heat transfer measurements using platinum thin film sensors are the flow diagnostics used. From the time resolved visualizations and surface pressure measurements with the fast response sensors, the flow field, even with a separation bubble as large as 75 mm (at Mach 5.96, with shock impingement at 95 mm from the leading edge) was found to be established within the short shock tunnel test time. The effects of various parameters- freestream Mach number, distance of the location of shock impingement, freestream total enthalpy and wall heat transfer- on the interaction are investigated. With increase in Mach number from 5.96 to 8.67, for nearly the same shock impingement locations (95 mm and 100 mm from the leading edge respectively), the separation length decreased from 75 mm to 60 mm despite the fact that the shocks are doubly stronger at the higher Mach number. Inflectional trend in separation length was observed with enthalpy at nominal Mach number 8- separation length increased from 60 mm at 1.6 MJ/kg to 70 mm at 2.4 MJ/kg, and decreased drastically to ~40 mm at 6 MJ/kg (when dissociations are expected). The separation length Lsep for all the experiments, except the experiments at 6 MJ/kg, were found to be large, i.e. comparable with the distance xi of location of shock impingement from the leading edge of the flat plate. The scaled separation length (with Hylem wall) was found to obey the inviscid similarity law proposed from the present study for large separation bubbles with strong impinging shocks, where M∞ is the freestream Mach number, p∞ is the freestream pressure and pr is the measured reattachment pressure; this holds for freestream total enthalpy ranging from 1.3 MJ/kg to 2.4 MJ/kg and Reynolds number (based on location of shock impingement) ranging from 1x105 to 4x105. While the increase in separation length from 1.6 MJ/kg to 2.4 MJ/kg could thus be attributed to the small difference in Mach number between the cases (due to inverse variation with cube of Mach number), the decrease in separation length and the non-confirmation to the proposed similarity law for the 6 MJ/kg case is attributed to the real gas effects. At Mach 6 the flow was observed to separate close to the leading edge, even when the (inviscid) shock impingement was at 95 mm from the leading edge. This prompted the proposal of an approximate inviscid model of the interaction for the Mach 6 case with separation at leading edge, and reattachment at the location of (inviscid) shock impingement; Accordingly, the closer the location of impingement, the more the angle that the separated shear layer makes with the plate and hence more the pressure inside the separation bubble. A small reduction in separation length was also observed with aluminium wall when compared with Hylem wall, emphasizing the importance of wall heat conductivity (especially when concerning separated flows) even within the short test durations of shock tunnels. The free interaction theory over adiabatic wall was found to predict the pressure at the location of separation, but under-predict the plateau pressure (at nominal Mach number 8). Numerical simulations (steady, planar) were also carried out using commercial CFD solver FLUENT to complement the experiments. Simulations using one equation turbulence model (Spalart-Allmaras model) were closer to the experimental results than the laminar simulations, suggesting that the flow field may be transitional or turbulent after separation. Significant reduction of the separation bubble length was demonstrated with the control of the interaction using boundary layer bleed within the short test time of the shock tunnel; with tangential blowing at the separation location20% reduction in separation length was observed, while with suction at separation location the reduction was 13.33 %.

Shock-shock interactions are among the most basic gas-dynamic problem, and are almost unavoidable in any high speed light, where shock waves generating from different sources crosses each other paths. These interactions when present very close to the solid surface lead to very high pressure and thermal loads on the surface. The related practical problem is that experienced at the cowl lip of a scramjet engine, where the interfering shock waves leads to high heat transfer rates which may also lead to the damage of the material. The classification by Edney (1968) on the shock-shock interaction patterns based on the visualization has since then served the basis for such studies. Though the problem of high heating on the surface in the vicinity of the shock-shock interactions has been studied at length at supersonic Mach numbers, the study on the topic at the hypersonic Mach numbers is little sparse. Even in the studies at hypersonic Mach numbers, the high speeds are not simulated, which is the measure of the kinetic energy of the ow. Very few experimental studies have addressed this problem by simulating the energy content of the ow. Also, some of the numerical studies on the shock-shock interactions suggest the presence of unsteadiness in the shock-shock interaction patterns as observed by Edney (1968), though this observation is not made very clearly in the experimental studies undertaken so far. In the present study, experiments are carried out in a conventional shock tunnel at Mach number of 5.62 (total enthalpy of 1.07 MJ/kg; freestream velocity of 1361 m/s), with the objective of mapping the surface pressure distribution and surface convective heat transfer rate distribution on the hemispherical body in the presence of the shock-shock interactions. A shock generator which is basically a wedge of angle = 25 , is placed at some dis-dance in front of the hemispherical body such that the planar oblique shock wave from the shock generator hits the bow shock wave in front of the hemi-spherical body. The relative distance between the wedge tip and the nose of the hemispherical body is allowed to change in di erent experiments to capture the whole realm of shock-shock interaction by making the planar oblique shock wave interact with the bow shock wave at different locations along its trajectory. The study results in a bulk of data for the surface pressure and heat transfer rates which were obtained by placing 5 kulites pressure transducers, 1 PCB pressure transducer and 21 platinum thin lm gauges along the surface of the hemispherical body in a plane normal to the freestream velocity direction. Along with the measurement of the surface pressure and the surface heat transfer rates, the schlieren visualization is carried out to capture the shock waves, expansion fans, slip lines, present in a certain shock-shock interaction pattern and the measured values were correlated with the captured schlieren images to evaluate the ow build up and steady and useful test time thereby helping in understanding the ow physics in the presence of the shock-shock interactions. From the present study it has been observed that in the presence of Edney Type-I and Edney Type-II interaction, the heat transfer rates on the hemi-spherical body are symmetrical about the centerline of the body, with the peak heating at the centerline which drops towards the shoulder. For Edney Type-III, Edney Type-IV, Edney Type-V and Edney Type-VI interaction pattern, the distribution in not symmetrical and shifts in peak heat transfer rates being on the side of the hemispherical from which planar oblique shock wave is incident. Also, it is observed that for the interactions which appear within the sonic circle, Edney Type-III and Edney Type-IV, the heat transfer rates observe an unsteadiness, such that the gauges located close to the interaction region experiencing varying heat transfer rates during the useful test time of the shock tunnel. Few experiments were conducted at Mach 8.36 (total enthalpy of 1.29 MJ/kg; freestream velocity of 1555.25 m/s) and Mach 10.14 (total enthalpy of 2.67 MJ/kg; freestream velocity of 2258.51 m/s) for the con gurations representing Edney Type-III interaction pattern to further evaluate the unsteady nature observed at Mach 5.62 ows. The unsteadiness was evident in both the cases. It is realized that the short test times in the shock tunnels pose a constraint in the study of unsteady flow fields, and the use of tailored mode operation of shock tunnel can alleviate this constraint. Also, limited number of experiments in the present study, which are carried out in a Free Piston Shock Tunnel, helps to understand the need to conduct such study in high enthalpy test conditions.

The results from computer simulations of the gas-dynamic processes that occur during and after the rupture of diaphragms within shock tubes and expansion tubes are presented. A two-dimensional and axisymmetric finite-volume code that solves the unsteady Euler equations for inviscid compressible flow, was used to perform the simulations. The flow domains were represented as unstructured meshes of triangular cells and solution-adaptive remeshing was used to focus computational effort in regions where the flow-field gradients were high. The ability of the code to produce accurate solutions to the Euler equations was verified by examining the following test cases: supersonic vortex flow between two arcs, an ideal shock tube, and supersonic flow over a cone. The ideal shock tube problem was studied in detail, in particular the shock speed. The computed shock speed was accurate when the initial pressure ratio was low. When the initial pressure ratio was high the ow was dificult to resolve because of the large density ratio at the contact surface where significant numerical diffusion occurred. However, solution- adaptive remeshing was used to control the error and reasonable estimates for the shock speed were obtained. The code was used to perform multi-dimensional simulations of the gradual opening of a primary diaphragm within a shock tube. The development of the flow, in particular the contact surface was examined and found to be strongly dependent on the initial pressure ratio across the diaphragm. For high initial pressure ratios across the diaphragm, previous experiments have shown that the measured shock speed can exceed the shock speed predicted by one- dimensional models. The shock speeds computed via the present multi-dimensional simulation were higher than those estimated by previous one-dimensional models and were closer to the experimental measurements. This indicates that multi- dimensional ow effects were partly responsible for the relatively high shock speeds measured in the experiments. The code also has the ability to simulate two-dimensional fluid-structure interac- tions. To achieve this the Euler equations are solved for a general moving frame of reference. Mesh management during a simulation is important. This includes the ability to automatically generate a new mesh when the current mesh becomes distorted (due to the motion of the structures) and the transfer of the solution from the old mesh to the new. The shock induced rupture of thin diaphragms was examined. Previous one dimen- sional models are awed because they do not simultaneously consider the diaphragm mass and allow the upstream gas to penetrate the diaphragm mass. Two multi- dimensional models which allow the upstream gas to penetrate are described. The first model assumes the diaphragm vaporises immediately after the arrival of the incident shock. The second model assumes the diaphragm shatters into a number of pieces which can be treated as rigid bodies. The results from both models are compared with experimental data.

Aerodynamic cavities are common features on hypersonic vehicles which are caused in both large and small scale features like surface defects, pitting, gap in joints etc. In the hypersonic regime, the presence of such cavities alters the flow phenomenon considerably and heating rates adjacent to the discontinuities can be greatly enhanced due to the diversion of flow. Since the 1960s, a great deal of theoretical and experimental research has been carried out on cavity flow physics and heating. However, most of the studies have been done to characterize the effect downstream and within the cavity. In the present study, a series of were carried out in the shock tunnel to investigate the heating characteristics, upstream and on the lateral side of the cavity. Heat flux measurement has been done using indigenously developed high resistance platinum thin film gauges. High resistance gauges, as contrary to the conventionally used low resistance gauges were showing good response to the extremely low heat flux values on a flat plate with sharp leading edge. The experimental measurements of heat done on a flat plate with sharp leading edge using these gauges show good match with theoretical relation by Crabtree et al. Flow visualization using high speed camera with the cavity model and shock structures visualized were similar to reported in supersonic cavity flow. This also goes to state that in spite of the fluctuating shear layer-the main feature of hypersonic flow over a cavity ,reasonable studies can be done within the short test time of shock tunnel. Numerical Simulations by solving the Navier-Stokes equation, using the commercially available CFD package FLUENT 13.0.0 has been done to complement the experimental studies.

The growing requirements to achieve hypersonic flights, as in the case of reentry vehicles, pose a serious challenge to the designers. This demands an understanding of the features of hypersonic flow and its effect on hypersonic vehicles. Hypersonic shock tunnels are one of the most widely used facilities for the purpose of obtaining valuable design data by conducting experiments on scaled down models. They are operated by conventional shock tubes by rupturing metal diaphragms placed between the driver and driven sections of the shock tube. Shock tunnels are being extensively used in spite of some of the drawbacks they possess. Due to the varying nature of metal diaphragm rupture, reproducibility of the experiment results is difficult to obtain. Damage to model and inner surface of the shock tube can happen when the diaphragm petal breaks away from the diaphragm. Lastly the time consuming diaphragm replacement process is not desired in applications which require quick loading of shock waves on the specimen. All these disadvantages call for the replacement of the diaphragm mode of operation with a diaphragmless mode of operation for the generation of shock waves. The main objective of the present study is to design and demonstrate the working of a diaphragmless hypersonic shock tunnel. The motivation for the present study comes from the fact that the diaphragmless operation of a shock tunnel has not been reported so far in the open literature. All the research works carried out deal with diaphragmless drivers operating only a shock tube. In the present work, the conventional metal diaphragm is substituted by fast acting pneumatic valves which serve the purpose of quickly opening the driven section of the shock tube to allow the driver gas to rush in, resulting in the formation of a shock wave. To design a diaphragmless driver, a detailed study of the shock formation process is accomplished which helps in understanding the effect of valve opening time on the shock formation distance. Also the theoretical basis for the design of a pneumatic cylinder is understood. Following the theoretical studies, three types of diaphragmless drivers are designed and tested. The first setup incorporates a rubber membrane, which acts as a valve. The rubber membrane when bulged closes the mouth of the driven section and on retraction the driven section is opened to the driver gas. The second and the third setups utilise two different types of double acting pneumatic cylinders. Experimental results of the three diaphragmless drivers operating a shock tube are analysed and compared with the ideal shock tube theory. Better repeatability in terms of shock Mach number is shown with all three diaphragmless shock tubes when compared with a conventionally operated shock tube. Finally, the best among the three systems is identified to operate the hypersonic shock tunnel 2 (HST2) facility of the Shock Waves laboratory, IISc. Demonstration of the working of the diaphragmless shock tunnel is shown by performing heat transfer measurements on a 3 mm backward facing step flat plate model. The experimental results are compared with those obtained in a conventional shock tunnel. CFD studies on diaphragmless shock tube model are done to have an idea on the flow in the shock tube there by identifying the shock formation distance. ANSYS-CFX package is used for this purpose. Further, results from the numerical simulation of hypersonic flow over the backward facing step model are compared with the experimental results thus validating the code.

Knowledge of flow separation is very essential for proper understanding of both external and internal aerothermodynamics of bodies. Because of unique flow features such as thick boundary layers, merged shock layers, strong entropy layers, flow separation in the flow field of bodies at hypersonic speeds, is both complex as well as interesting. The problem of flow separation is further complicated at very high stagnation enthalpies because of the real gas effects. Notwithstanding the plethora of information available in open literature even for simple geometric configurations the experimentally determined locations of flow separation and re-attachment points do not match well with the results from the computational studies even at hypersonic laminar flow conditions. In this backdrop the main aim of the present study is to generate a reliable experimental database of classical separated flow features around generic configurations at hypersonic laminar flow conditions. In the present study, flow visualization using high speed camera, surface convective heat transfer rate measurements using platinum thin film sensors, and direct skin friction measurements using PZT crystals have been carried out for characterizing the separated flow field around backward facing step, double cone and double wedge models. The numerical simulations by solving the Navier-Stokes equations have also been carried out to complement the experimental studies. The generic models selected in the present study are simple configurations, where most of the classical hypersonic separated flow features of two-dimensional, axi-symmetric and three dimensional flow fields can be observed. All the experiments are carried out in IISc hypersonic shock tunnel (HST2) at Mach 5.75 and 7.6. For present study, helium and air have been used as the driver and test gases respectively. The high speed schlieren flow visualization is carried out on backward facing step (2 and 3 mm step height), double cone (semi-apex angles of 150/350 and 250/680) and double wedge (semi-apex angles of 150/350) models by using high speed camera (Phantom 7.1). From the visualized shockwave structure in the flow field the flow reattachment point after separation has been clearly identified for backward facing step, double cone and double wedge models at hypersonic Mach numbers while the separation point could not be clearly identified because of the low free stream density in shock tunnels. However the flow visualization studies helped clearly identifying the region of flow separation on the model. Based on the results from the flow visualization studies both the physical location and distribution of platinum thin film gauges was finalized for the heat transfer rate measurements. Surface heat transfer rates along the length of two backward facing step (2 and 3 mm step height) models have been measured using platinum thin film gauges deposited on Macor substrate. The Eckert reference temperature method is used along the flat plate for predicting the heat flux distribution. Theoretical analysis of heat flux distribution down stream of the backward facing step model has been carried out using Gai’s dimensional analysis. The study reveals for the first time that at moderate stagnation enthalpy levels (~2 MJ/kg) the hypersonic separated flow around a backward facing step reattaches rather smoothly without any sudden spikes in the measured values of surface heat transfer rates. Based on the measured surface heating rates on the backward facing step, the reattachment distance was estimated to be approximately 10 and 8 step heights downstream of 2 and 3 mm step respectively at nominal Mach number of 7.6. Convective surface heat transfer experiments have also been carried out on axi-symmetric double cone models (semi-apex angles of 15/35 and 25/68), which is analogous to the Edney’s shock interactions of Type VI and Type IV respectively. The flow is unsteady on the double cone model of 25/68 and measured heat flux is not constant. The heat transfer experiments were also carried out on the three-dimensional double wedge model (semi-apex angles of 15/35). The separation and reattachment points have been clearly identified from the experimental heat transfer measurements. It has been observed that the measured heat transfer rates on the double wedge model is less than the double cone model (semi-apex angles of 150/350) for the identical experimental conditions at the same gauge locations. This difference could be due to the three-dimensional entropy relieving effects of double wedge model. PZT-5H piezoelectric based skin friction gauge is developed and used for direct skin friction measurements in hypersonic shock tunnel (HST2). The bare piezoelectric PZT-5H elements (5 mm × 5 mm with thickness of 0.75 mm) polarized in the shear mode have been used as a skin friction gauge by operating the sensor in the parallel shear mode direction. The natural frequency of the skin friction sensor is ~80 kHz, which is suitable for impulse facilities. The direct skin friction measurements are carried out on flat plate, backward facing step (2 mm step height) and double wedge models. The measured value of skin friction coefficient (integrated over an area of 25 sq. mm; sensor surface area) at a distance of 23 mm from the leading edge of the sharp leading edge backward facing step model is found to be ~ 0.0043 while it decreases to ~ 0.003 at a distance of 43 mm from the leading edge at a stagnation enthalpy of ~ 2MJ/kg. The measured skin friction matches with the Eckert reference temperature within ± 10%. The skin friction coefficient is also measured on the double wedge at a distance of 73 mm from the tip of the first wedge along the surface and is found to be 4.56 × 10-3. Viscous flow numerical simulations are carried out on two-dimensional backward facing step, axi-symmetric double cone and three-dimensional double wedge models using ANSYS-CFX 5.7 package. Navier-Stokes Simulations are carried out at Mach 5.75 and 7.6 using second order accurate (both in time and space) high resolution scheme. The flow is assumed to be laminar and steady throughout the model length except on the double cone (semi-apex angles of 250/680) model configuration, which represents the unsteady flow geometry. Analogous Edney Type VI and Type IV shock interactions are observed on double cone, double wedge (semi-apex angles of 150/350) and double cone (semi-apex angles of 250/680) models respectively from the CFD results. Experimentally measured convective heat transfer rates on the above models are compared with the numerical simulation results. The numerical simulation results matches well with the experimental heat transfer data in the attached flow regions. Considerable differences are observed between the measured surface heat transfer rates and numerical simulations both in the separated flow region and on the second cone/wedge surfaces. The separation and reattachment points can be clearly identified from both experimental measurements and numerical simulations. The results from the numerical simulations are also compared with results from the high speed flow visualization experiments. The experimental database of surface convective heating rates, direct skin friction coefficient and shockwave structure in laminar hypersonic flow conditions will be very useful for validating CFD codes

Hypersonic vehicles are exposed to severe heating loads during their flight in the atmosphere. In order to minimize the heating problem, a variety of cooling techniques are presently available for hypersonic blunt bodies. Introduction of a forward-facing cavity in the nose tip of a blunt body configuration of hypersonic vehicle is one of the most simple and attractive methods of reducing the convective heating rates on such a vehicle. In addition to aerodynamic heating, the overall drag force experienced by vehicles flying at hypersonic speeds is predominate due to formation of strong shock waves in the flow. Hence, the effective management of heat transfer rate and aerodynamic drag is a primary element to the success of any hypersonic vehicle design. So, precise information on both aerodynamic forces and heat transfer rates are essential in deciding the performance of the vehicle. In order to address the issue of both forces and heat transfer rates, right kind of measurement techniques must be incorporated in the ground-based testing facilities for such type of body configurations. Impulse facilities are the only devices that can simulate high altitude flight conditions. Uncertainties in test flow conditions of impulse facilities are some of the critical issues that essentially affect the final experimental results. Hence, more reliable and carefully designed experimental techniques/methodologies are needed in impulse facilities for generating experimental data, especially at hypersonic Mach numbers. In view of the above, an experimental program has been initiated to develop novel techniques of measuring both the aerodynamic forces and surface heat transfer rates. In the present investigation, both aerodynamic forces and surface heat transfer rates are measured over the test models at hypersonic Mach numbers in IISc hypersonic shock tunnel HST-2, having an effective test time of 800 s. The aerodynamic coefficients are measured with a miniature type accelerometer based balance system where as platinum thin film sensors are used to measure the convective heat transfer rates over the surface of the test model. An internally mountable accelerometer based balance system (three and six-component) is used for the measurement of aerodynamic forces and moment coefficients acting on the different test models (i.e., blunt cone with after body, blunt cone with after body and frustum, blunt cone with after body-frustum-triangular fins and sharp cone with after body-frustum-triangular fins), flying at free stream Mach numbers of 5.75 and 8 in hypersonic shock tunnel. The main principle of this design is that the model along with the internally mounted accelerometer balance system are supported by rubber bushes and there-by ensuring unrestrained free floating conditions of the model in the test section during the flow duration. In order to get a better performance from the accelerometer balance system, the location of accelerometers plays a vital role during the initial design of the balance. Hence, axi-symmetric finite element modeling (FEM) of the integrated model-balance system for the missile shaped model has been carried out at 0° angle of attack in a flow Mach number of 8. The drag force of a model was determined using commercial package of MSC/NASTRAN and MSC/PATRAN. For test flow duration of 800 s, the neoprene type rubber with Young’s modulus of 3 MPa and material combinations (aluminum and stainless steel material used as the model and balance) were chosen. The simulated drag acceleration (finite element) from the drag accelerometer is compared with recorded acceleration-time history from the accelerometer during the shock tunnel testing. The agreement between the acceleration-time history from finite-element simulation and measured response from the accelerometer is very good within the test flow domain. In order to verify the performance of the balance, tests were carried out on similar standard AGARD model configurations (blunt cone with cylinder and blunt cone with cylinder-frustum) and the results indicated that the measured values match very well with the AGARD model data and theoretically estimated values. Modified Newtonian theory is used to calculate the aerodynamic force coefficient analytically for various angles of attack. Convective surface heat transfer rate measurements are carried out by using vacuum sputtered platinum thin film sensors deposited on ceramic substrate (Macor) inserts which in turn are embedded on the metallic missile shaped body. Investigations are carried out on a model with and without fin configurations in HST-2 at flow Mach number of 5.75 and 8 with a stagnation enthalpy of 2 MJ/kg for zero degree angle of attack. The measured heating rates for the missile shaped body (i.e., with fin configuration) are lower than the predicted stagnation heating rates (Fay-Riddell expression) and the maximum difference is about 8%. These differences may be due to the theoretical values of velocity gradient used in the empirical relation. The experimentally measured values are expressed in terms of normalized heat transfer rates, Stanton numbers and correlated Stanton numbers, compared with the numerically estimated results. From the results, it is inferred that the location of maximum heating occurs at stagnation point which corresponds to zero velocity gradient. The heat-transfer ratio (q1/Qo)remains same in the stagnation zone of the model when the Mach number is increased from 5.75 to 8. At the corners of the blunt cone, the heat transfer rate doesn’t increase (or) fluctuate and the effects are negligible at two different Mach numbers (5.75 and 8). On the basis of equivalent total enthalpy, the heat-transfer rate with fin configuration (i.e., at junction of cylinder and fins) is slightly higher than that of the missile model without fin. Attempts have also been made to evaluate the feasibility of using forward facing cavity as probable technique to reduce the heat transfer rate and to study its effect on aerodynamic coefficients on a 41° apex angle missile shaped body, in hypersonic shock tunnel at a free stream Mach number of 8. The forward-facing circular cavities with two different diameters of 6 and 12 mm are chosen for the present investigations. Experiments are carried out at zero degree angle of attack for heat transfer measurements. About 10-25 % reduction in heat transfer rates is observed with cavity at gauge locations close to stagnation region, whereas the reduction in surface heat transfer rate is between 10-15 % for all other gauge locations (which is slightly downstream of the cavity) compared with the model without cavity. In order to understand the influence of forward facing cavities on force coefficients, measurement of aerodynamic forces and moment coefficients are also carried out on a missile shaped body at angles of attack. The same six component balance is also being used for subsequent investigation of force measurement on a missile shaped body with forward facing cavity. Overall drag reductions of up to 5 % is obtained for a cavity of 6 mm diameter, where as, for the 12 mm cavity an increase in aerodynamic drag is observed (up to about 10%). The addition of cavity resulted in a slight increase in the missile L/D ratio and did not significantly affect the missile lateral components. In summary, the designed balances are found to be suitable for force measurements on different test models in flows of duration less than a millisecond. In order to compliment the experimental results, axi-symmetric, Navier-Stokes CFD computations for the above-defined models are carried out for various angles of attack using a commercial package CFX-Ansys 5.7. The experimental free stream conditions obtained from the shock tunnel are used for the boundary conditions in the CFD simulation. The fundamental aerodynamic coefficients and heat transfer rates of experimental results are shown to be in good agreement with the predicted CFD. In order to have a feeling of the shock structure over test models, flow visualization experiments have been carried out by using the Schlieren technique at flow Mach numbers of 5.75 and 8. The visualized shock wave pattern around the test model consists of a strong bow shock which is spherical in shape and symmetrical over the forebody of the cone. Experimentally measured shock stand-off distance compare well with the computed value as well as the theoretically estimated value using Van Dyke’s theory. These flow visualization experiments have given a factual proof to the quality of flow in the tunnel test section.

Hypersonic flow is both fascinating and intriguing mainly because of presence of strong entropy and viscous interactions in the flow field. Notwithstanding the tremendous advancements in numerical modeling in the last decade separated hypersonic flow still remains an area where considerable differences are observed between experiments and numerical results. Lack of reliable data base of surface static pressures with good spatial resolution in hypersonic separated flow field is one of the main motivations for the present study. The experiments in hypersonic shock tunnels has an advantage compared to wind tunnels for simulating the total energy content of the flow in addition to the Mach and Reynolds numbers. However the useful test time in shock tunnels is of the order of few milliseconds. Hence in shock tunnel experiments it is essential to have pressure measurement devices which has special features such as small in size, faster response time and the sensors in array form with improved spatial resolutions. Micro Electro Mechanical Systems (MEMS) is an emerging technology, which holds lot of promise in these types of applications. In view of the above requirement, MEMS based pressure sensor array was developed to measure the static pressure distribution. The study is comprised of two parts: one is on the development of MEMS based pressure sensor array, which can be used for hypersonic application and other is on experimental static pressure measurement using MEMS based sensors in separated hypersonic flow over a backward facing step model. Initially a static pressure sensor array with 25 sensors was developed. The static calibration of sensor array was carried out to characterize the sensor array for various characteristic parameters. The preliminary experimental study with cluster of 25 MEMS sensor array mounted on the flat plate did not provide reliable and repeatable results, but gave valuable inputs on the typical problems of using MEMS sensors in short duration hypersonic ground test facilities like shock tunnels. Incidentally, to the best of our knowledge this is first report on use of MEMS based pressure sensors in hypersonic shock tunnel. Later cluster of 5 sensor array was developed with improved electronic packaging and surface finish. The experiments were conducted with flat plate by mounting 5 sensor array shows good agreement in static pressure measurement compared with standard sensors. In the second part of the study a backward facing step model, which simulates the typical gasdynamic flow features associated with hypersonic flow separation is designed. Backward facing step model with step height of 3 mm was mounted with sensor array along the length of model. Just after the step, static pressure measurements were carried out with MEMS sensors. It is important to note that, in the space available in backward facing step model we could mount only one conventional Kulite pressure transducer. The experiments were conducted at Mach number of 6.3 and at stagnation enthalpy of 1.5 MJ/kg in hypersonic shock tunnel (HST-5) at IISc. Based on the static pressure measurement on backward facing step, the location of separation and reattachment points were clearly identified. The static pressure values show that reattachment of flow takes place at about 7 step heights. Numerical simulations were carried out using commercial CFD code, FLUENT for flat plate and backward facing step models to compliment the experiments. The experimental tests results match well with the illustrative numerical simulations results.

With the age of hypersonic flight imminent just beyond the horizon, researchers are working hard at designing work-arounds for all the major problems as well as the minor quirks associated with it. One such issue, seemingly innocuous but one that could be potentially deadly, is the problem of interference heating due to surface protuberances. Although an ideal design of the external surfaces of a high-speed aircraft dictates complete smoothness to reduce drag, this is not always possible in reality. Control surfaces, sheet joints, cable protection pads etc. generate surface discontinuities of varying geometries, in the form of both protrusions as well as cavities. These discontinuities are most often small in dimension, comparable to the local boundary layer thickness at that location. Such protuberances always experience high rates of heat transfer, and therefore should be appropriately shielded. However, thermal shielding of the protrusions alone is not a full solution to the problem at hand. The interference caused to the boundary layer by the flow causes the generation of local hot spots in the vicinity of the protuberances, which should be properly mapped and adequately addressed. The work presented in this thesis aims at locating and measuring the heat flux values at these hot spots near the protrusions, and possibly formulating empirical correlations to predict the hot spot heat flux for a given set of flow conditions and protrusion geometry. Experimental investigations were conducted on a flat plate model and a cone model, with interchangeable sharp and blunt nose tips, with attached 3D protuberances. Platinum thin-film sensors were placed around the protrusion so that the heat fluxes could be measured in its vicinity and the hottest spot located. These experiments were carried out at five different hypersonic free stream flow conditions generated using two shock tunnels, one of the conventional type, and the other of the free-piston driven type. The geometry of the protrusions, i.e., the height and the deflection angle, was also parametrically varied to study its effect on the hot spot heat flux. The results thus obtained for the flat plate case were compared to existing correlations in the open literature from a similar previous study at a much higher Reynolds number range. Since a mismatch was observed between the results of the current experiments and the existing correlations, a new empirical correlation has been developed to predict the hot spot heat flux, that is valid within the range of flow conditions studied here. A similar attempt was made for the case of the cone model, for which no previous correlations exist in the open literature. However, a global correlation covering the entire range of flow conditions used here could not be formed. A correlation that is valid for just one out of the five flow conditions used here is presented for the cones with sharp and blunt nose tips separately. Schlieren flow visualization was carried out to obtain a better understanding of the shock structures near the protuberances on both models. For most cases, where the protrusion height and deflection angle were large enough to cause flow separation immediately upstream of the protuberance, a separation shock was manifested which deflected some part of the boundary layer above the protuberance, while the rest of the fluid in the boundary layer entered a recirculating region in the separated zone before escaping to the side. Some preliminary computational analysis was conducted which confirmed this qualitatively. However, the quantitative match of surface heat flux between the simulations and experiments were not encouraging. Schlieren visualization revealed that for the flat plate case, the foot of the separation shock was located at a distance of 10.5 to 12 times the protrusion height ahead of it, whereas in the case of the sharp cone, it was at a distance of 9 to 10.5 times the protrusion height. The unsteady nature of the separation shock was also captured and addressed. Some preliminary experiments on boundary layer tripping were also conducted, the results of which have been presented here. From this analysis, it has become evident that a single global correlation cannot be formed which could be used for a wide range of flow conditions to predict the hot spot heat flux in interference interactions. The entire range of conditions that may be encountered during hypersonic flight has to be broken down into sections, and the interference heating pattern should be studied in each of these sections individually. By doing so, a series of different correlations can be formed at the varying flow conditions which will then be available for high-speed aircraft designers.