M.S.

Two steel pipe piles in place in abutments for two different bridge constructions sites were instrumented with strain gauges to measure the magnitude of negative skin friction. The piles were monitored before, during and up to 19 months after construction was completed. The load versus depth and time in each pile is discussed. Maximum observed dragloads ranged from 98 to 127 kips. A comparison with two methods for calculating dragloads is presented. Both comparison methods were found to be conservative, with the Briaud and Tucker (1997) approach more closely estimating the observed load versus depth behavior.

A direct, simple, and accurate way to measure skin friction by oil-film laser interferometry has been developed by various researchers. Equations and methods were developed to correct measurement errors arising from three-dimensional effects and pressure gradients. The oil-film, dual-beam laser interferometer was constructed to measure the skin friction around a wing-body junction in a three-dimensional, turbulent boundary layer with pressure gradients. The flow was dominated by the formation of a junction vortex generated at the nose of the wing-body. The oil-film skin friction results were compared with previous skin-friction measurements for the flow obtained by hot-wire measurements. The skin friction values agreed within approximately 8% between the two methods. The effects and benefits of scanning laser interferometry and alternative beam directions were investigated and discussed. The effect of dirt contamination on the data is also discussed. Methods to improve the data quality are presented. / Master of Science

The purpose of the project was to examine fiber optic sensors for the measurement of pressure, skin friction, temperature, and heat flux in high Reynolds number, supersonic flow. Using a standard fiber optic signal conditioning unit (specifically a broadband interferometric system using spectra), the work centered around determining under what conditions these sensors will work effectively and quantifying the total system limitations. An interferometric-based, fiber optic skin friction sensor was developed for the measurement of wall shear stress in complex, supersonic flows. This sensor type was tested successfully in laminar, incompressible flow, and supersonic flow up to Mach 1.92, Mach 2.4 and 3.0 flow, in which the sensor operated with varying success. A micromachined, fiber optic pressure sensor was also tested in these supersonic conditions, also with varying success. The accurate operation of these sensors was found to be tied to the flow conditions and the fiber optic, signal processing system. A correlation was found to exist between the energy of the flow, either through its dynamic pressure or through external disturbances such as shocks or separation, and the noise in the signals, expressed by the variance of the gap estimate, for the pressure and skin friction sensors in these flows. The energy of the flow couples with the mechanical properties of the sensor reducing the fringe contrast of the signal used by the optical signal processing system to determine a gap estimate. As the energy of the flow is increased and the sensor is excited, the fringe contrast is reduced. A practical limit of a normalized fringe contrast of 0.10 was found for producing accurate gap estimates in real flows. A consequence is that there is a limit to the dynamic pressure of the flow for the sensors to operate accurately, which is demonstrated by the varying success of the supersonic wind tunnel tests. This correlation is sensor specific, meaning that sensors can be designed to operate successfully in any flow. Also, the signal processing system, which forms the other end of the total system, could be improved to allow accurate measurements with the current sensors. / Ph. D.

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.

A series of direct-measuring skin friction gages were developed for a high-speed, high-temperature environment of the turbulent boundary layer in flows such as that in supersonic combustion ramjet (scramjet) engines, with a progression from free-jet ground tests to a design for an actual hypersonic scramjet-integrated flight vehicle. The designs were non-nulling, with a sensing head that was flush with the model wall and surrounded by a small gap. Thus, the shear force due to the flow along the wall deflects the head, inducing a measurable strain. Strain gages were used to detect the strain. The gages were statically calibrated using a direct force method. The designs were verified by testing in a well-documented Mach 2.4 cold flow. Results of the cold-flow tests were repeatable and within 15% of the value of Cf estimated from simple theory. The first gage design incorporated a cantilever beam with semiconductor strain gages to sense the shear on the floating head. Cooling water was routed both internally and around the external housing in order to control the temperature of the strain gages. This first gage was installed and tested in a rocket-based-combined-cycle (RBCC) engine model operating in the scramjet mode. The free-jet facility provided a Mach 6.4 flow with P0 = 1350 psia (9310 kPa) and T0 = 2800 °R (1555 °K). Local wall temperatures were measured between 850 and 900 °R (472-500 °K). Output from the RBCC scramjet tests was reasonable and repeatable. A second skin friction gage was designed for and tested in a wind tunnel model of the Hyper-X flight vehicle scramjet engine. These unsuccessful tests revealed the need for a radically different skin friction gage design. The third and final skin friction gage was specifically developed to be installed on the Hyper-X flight vehicle. Rather than the cantilever beam and semiconductor strain gages, the third skin friction gage made use of a flexure ring and metal foil strain gages to sense the shear. The water-cooling and oil-fill used on the previous skin friction sensors were eliminated. It was qualified for flight through a rigorous series of environmental tests, including pressure, temperature, vibration, and heat flux tests. Finally, the third skin friction gage was tested in the Hyper-X Engine Model (HXEM), a full-scale-partial-width wind tunnel model of the flight vehicle engine. These tests were conducted at Mach 6.5 enthalpy with P0 = 555 psia (3827 kPa) and h0 = 900 Btu/lbm in a freejet facility. The successful testing in the wind tunnel scramjet model provided the final verification of the gage before installation in the flight vehicle engine. The development, testing, and results of all three skin friction gages are discussed. / Ph. D.

This investigation concerns the design, analysis, and initial testing of a new, two-component wall shear gage for 3D, high-temperature flows. This gage is a direct-measuring, non-nulling design with a round head surrounded by a small gap. Two flexure wheels are used to allow small motions of the floating head. Fiber-optic displacement sensors measure how far the polished faces of counterweights on the wheels move in relation to a fixed housing as the primary measurement system. No viscous damping was required. The gage has both fiber-optic instrumentation and strain gages mounted on the flexures for validation of the newer fiber optics. The sensor is constructed of Haynes 230, a high-temperature nickel alloy. The gage housing is made of 316 stainless steel. All components of the gage in pure fiber-optic form can survive to a temperature of 1073 K. The bonding methods of the backup strain gages limit their maximum temperature to 473 K. The dynamic range of the gage is from 0-500 Pa (0-10g) and higher shears can be measured by changing the floating head size. Extensive use of finite element modeling was critical to the design and analysis of the gage. Static structural, modal, and thermal analyses were performed on the flexures using the ANSYS finite element package. Static finite element analysis predicted the response of the flexures to a given load, and static calibrations using a direct force method confirmed these results. Finite element modal analysis results were within 16.4% for the first mode and within 30% for the second mode when compared with the experimentally determined modes. Vibration characteristics of the gage were determined from experimental free vibration data after the gage was subjected to an impulse. Uncertainties in the finished geometry make this level of error acceptable. A transient thermal analysis examined the effects of a very high heat flux on the exposed head of the gage. The 100,000 W/m2 heat flux used in this analysis is typical of a value in a scramjet engine. The gage can survive for 10 minutes and operate for 3 minutes before a 10% loss in flexure stiffness occurs under these conditions. Repeated cold-flow wind tunnel tests at Mach 2.4 with a stagnation pressure from 3.7-8.2 atm (55-120 psia) and ambient stagnation temperature (Re=6.6x107/m) and Mach 4.0 with a stagnation pressure from 10.2-12.2 atm (150-180 psia) and ambient stagnation temperature (Re=7.4x107/m) were performed in the Virginia Tech Supersonic Wind Tunnel. Some of these tests had the gage intentionally misaligned by 25o to create a virtual 3D flow in this nominally 2D facility. Experimental results gave excellent agreement with semi-empirical prediction methods for both the aligned and 25o experiments. This fiber-optic skin friction gage operated successfully without viscous damping. These tests in the supersonic wind tunnel validated this wall shear gage design concept. / Ph. D.

An investigation was conducted to design instruments to directly measure skin friction along the chamber walls of supersonic combustor models. Measurements were made in a combustor at the General Applied Science Laboratory (GASL) and in the Direct Connect Arcjet Facility (DCAF) supersonic combustor at the NASA AMES Research Center. Flow conditions in the high enthalpy combustor models ranged from total pressures of 275-800 psia (1900-5550 kPa) and total temperatures from 5800-8400 R (3222-4667 K). This gives enthalpies in the range of 1700-3300 BTU/Ib_m (3950-7660 KJ/kg) and simulated flight Mach number from 9 to 13. A direct force measurement device was used to measure the small tangential shear force resulting from the flow passing over a non-intrusive floating element. The floating head is mounted to a stiff cantilever beam arrangement with deflection due to the shear force on the order of 0.0005 in (0.0125 mm). This small deflection allows the balance to be a non-nulling type. Several measurements were conducted in cold supersonic flows to verify the concept and establish accuracy and repeatability. This balance design includes actively controlled cooling of the floating sensor head temperature through an internal cooling system to eliminate nonuniform temperature effects between the head and the surrounding chamber wall. This enabled the device to be suitable for shear force measurement in very hot flows. The key to this device is the use of a quartz tube cantilever with strain gages bonded at orthogonal positions directly on the surface at the base. A symmetric fluid flow was developed inside the quartz tube to provide cooling to the backside of the floating head. Bench tests showed that this did not influence the force measurement. Numerical heat transfer calculations were conducted for design feasibility and analysis, and to determine the effectiveness of the active cooling of the floating head. Analysis of the measurement uncertainty in cold supersonic flow tests show that uncertainty under 8% is achievable, but variations in the balance cooling during a particular test raised uncertainty up to 20% in these very hot flows during the early tests. Improvements to the strain gages and balance cooling reduced uncertainty for the later tests to under 15%. / 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

A cantilever beam type, capacitive sensing, skin friction gage has been developed. A prototype along with supporting electronics has been constructed. The cantilever beam gage is a change of area variable capacitive transducer. It is designed to measure the wall shear stress in a short duration, supersonic flow. The supporting electronics consists of an electrical oscillator for frequency modulation, and a frequency demodulator. The change in capacitance due to the shear stress in the flow modulates the output signal of the oscillator, which is then demodulated to extract a voltage signal which corresponds to the change in capacitance of the gage. The gage and the electronics were constructed from simple, inexpensive components for the purpose of proving the concept of a capacitive sensing transducer. static calibrations have been completed and statistical analysis has been done to test the performance of the gage. A 0.12 mV response due to the expected 98.1 g m/s2 force input of the skin friction of the Mach 2.9 design flow, over the 0.49 in2 (316.1 mm) area of the gage's sensing head, was measured as the average output of the skin friction gage instrumented with stainless steel strips. / Master of Science