AD-Ri4 292 AEROTHERM L WIND TUNNEL

TEST OF*THE SPACE SHUTTLE

OHS i/i(ORBITAL PRNEUVERIN..(U) RRNOLD ENGINEERING DEVELOPMENTU U C r CENTER ARNOLD AFS TN S A STEPANEK SEP 83iNCLRSSIFIED REDC-TSR-83-Y229F/G 22/2 NL

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F: AEDC-TSR-83-V29

AEROTHERMAL WIND TUNNEL TEST OF THE SPACE]

______SHUTTLE OPIS POD AFRSI MATERIAL

S. A. Stepanek

Caispan Field Services, Inc.

_______September 1983

Final Report for Period 27 May to 11 August 1983

Ac

Approved for public release; distribution unlimited.

ARNOLD ENGINEERING DEVELOPMENT CENTERARNOLD AIR FORCE STATION, TENNESSEE

AIR FORCE SYSTEMS COMMANDUNITED STATES AIR FORCE

84 04 19 108

- V%.

._,

NOTICES

When U. S. Government drawings, specifications, or other data are used for any purpose other than adefinitely related Government procurement operation, the Government thereby incurs no responsibilitynor any obligation whatsoever, and the fact that the government may have formulated, furnished, or inany way supplied the said drawings, specifications, or other data, is not to be regarded by implication or 7otherwise, or in any manner licensing the holder or any other person or corporation, or conveying anyrights or permission to manufacture, use, or sell any patented invention that may in any way be related

thereto. 6-.

References to named commercial products in this report are not to be considered in any sense as anendorsement of the product by the United States Air Force or the Government.

APPROVAL STATEMENT

This report has been reviewed and approved.

J. T. BESTAeronautical Systems Branch

* Deputy for Operations

Wk.

Approved for publication:

FOR THE COMMANDER

/ d

JOHN M. RAMPY, DirectorSAerospace Flight Dynamics TestDeputy for Operations

,56

-' Tis epot hs ben tvtecd nd aproedi'-

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UN- - - - T n -'. -%. . . - - - - .

1JNrLAq-9TVT~nSECURITY CLASSIFICATION OF THIS PAGE (When Dta 1 n-e.ed) _'_

REPORT DOCUMENTATION PAGE BEFORE COMTUTIORM1. REPORT NUMBER 2. GOVT ACCESSION NO. 3. RECIPIENT'S CATALOG NUMBER

AEDC-TSR-83-V29

4. TITLE (and Subtitle) S. TYPE OF REPORT & PERIOD COVEREDFinal Report for May 27 to '-'AEROTHERMAL WIND TUNNEL TEST OF THE SPACE SHUTTLE August Rpr 1983 M 2OMS POD AFRSI MATERIAL

6. PERFORMING O'AG. REPORT NUMBER

7. AUTNOR( ) s. CONTRACT OR GRANT NUMBER(s)

S. A. Stepanek, Calspan Field Services, Inc.

9. PERFORMING ORGANIZATION NAME AND ADDRESS 10. PROGRAM ELEMENT. PROJECT, TASK -" AREA & WORK UNIT NUMBERS

Arnold Engineering Development Center/DO P WORK UTMERSAir Force Systems Command Control No. 9E01 M

Arnold Air Force Station, TN 37389 C o .

* II. CONTROLLING OFFICE NAME AND ADDRESS 12. REPORT DATE

." NASA/JSC September 1983I ~1. NUMBER OF PAGES :Houston, TX 77058 NB OA

7014. MONITORING AGENCY NAME & ADORESS(if diilerent from Controllinl Ofice) IS. SECURITY CLASS. (o1 this report)

Uclassified

ISo. DECL ASSI FICATION/ DOWNGRADING r.SCHEDULE N/A

16. DISTRIBUTION STATEMENT (of this Report)

Approved for public release; distribution unlimited.

17. DISTRIBUTION STATEMENT (of the abstract entered in Block 20, if different from Report)

IS. SUPPLEMENTARY NOTES

. Available in Defense Technical Information Center (DTIC).

~ 19. KEY WORDS (Continue on reverse side if necesary ad Identify by block number)AFRSI aeroheatingOHS Pod space shuttle

. materials testing wind tunnel testingheat transfer

. ABSTRACT (Continue an reverse side It necessary ind identify by block number) Qnd tunnel tests on Advanced Flexible Reusable Surface Insulation 4AFRS15 used

to protect the Orbital Maneuvering System ji Pod of the Space Shuttle Orbiterwere performed in the von Karman Gas Dynamics Facility Aerothermal Wind Tunnel(C). A wedge was used to subject the AFRSI to the desired local flow conditionsin a free stream Mach 4 flow with the objective of duplicating the AFRSI materialfailure that occurred during the STS-6 flight. Selected results are presentedto illustrate the test techniques and typical data obtained.

DD o 1473 EDITION OF I NOV 65 1S OBSOLETE UNCLASSIFIED, ... SECURITY CLASSIFICATION OF THIS PAGE (hen Dte Entered)

aCONTENTS

R PageNOMENCLATURE . . . . . . . . . . .3 . .* . . * . 3

1.0 INTRODUCTION ..... . ....... o . . o . .. . . 62.0 APPARATUS2.1!' Test Failt ..

2.2 Test Article ... . . . . . . . .72.3 Test Instrumentation . .... ... 8

3.0 TEST DESCRIPTION3.1 Test Conditions . . . .... ... 103.2 Test Procedures .................... 103.3 Data Reduction .. • , 123.4 Uncertainty of Measurements ....... , , .... , 15

4.0 DATA PACKAGE PRESENTATION ..... . .. .. .... .. . 16REFERENCES . . . . . . . . . . . . . . . . . . . . . . . 17

APPENDIXES

I. ILLUSTRATIONS

Figure

1. Tunnel C - Aerothermal Mach 4 Configuration . .... 19 .'."2. Installation of Test Article - Feasibility Checkout Entry . 203. Feasibility Test Article in Tunnel Tank . . % a % % .e a l% 224, Aerotherm Wedge - Feasibility Checkout Entry . .. .. . 235. Feasibility Test Models ..... : .......... , 246. Installation of Test Article -Calibration and Material

Evaluation Entry . . ....... . ...... . . . , 257. Test Article - Calibration and Material Evaluation Entry 278. Contour of OMS Pod Test Models ....... . , . .* 299. Pressure Calibration Test Article ...... .. .. . 30

10. Thermal Calibration Test Article ....... . ...... 3211. Typical AFRSI Test Sample . . . . . . . . . . . . . . . . . . 3412. Tunnel-Exposed Test Articles......... . .... . 35

13. Typical Oil-Flow Visualization Data , 3914. Spatial Correlation of Digitized IR Data with Came;a*Field of 4

Vie andTest Artic.......... 40

II. TABLES K

a- 1. Cardon Heat Gage Locations . , ... ,.,., 422. Static Pressure Tap Locations 3. . . . . 433. Kulite Dynamic Pressure Gage Locations .. . .... 454. Coordinates of 0.2-Scale Partial OMS Pod Contour . . . . . . 465. Thermal Model Surface Thermocouple Locations ...... , . 476. AFRSI Sample Descriptions .... • . . . . . • . • . . . . . 477. Estimated Uncertainties .... . . . . . . . . . . . . . . 48

8. Photographic Data Summary . s ,, ° , . 519. Test Summary • . . . , •• . . . . . . . . . . . 52

-. P

Page

10. Summary of Data Acquisition and Tabular Print ..... . . 55

III. SAMPLE TABULATED DATA

1. Gardon Gage Data - Feasibility Checkout Entry. . ..... 572. Gardon Gage Data - Calibration and Material Evaluation Entry. 583. Thermocouple and Camera Data - Pressure Calibration . . . . . 594. Thermocouple and Camera Data - Thermal Calibration . . . . . 60

. 5. Thermocouple and Camera Data - Material Evaluation . . . . . 646. RMS Pressure Data - Pressure Calibration . ... 667. Static Pressure Data - Pressure Calibration . . . . . 67S. Static Pressure Data- Thermal Calibration and MaterialEvaluation ... .. *5 9

9. Infrared Data- Thermal Calibration and Material Evaluation . 70

S2

*% %

5...

NOMENCLATURE

ALPHA, Indicated pitch angle, degALPHA ANGLE

CI Gardon gage calibration factor measured at 70"F,Btu/ft -sec-mv

C2 Temperature colrected Gardon gage calibrationfactor, Btu/ft -sec-mv

CL Tunnel event indication of model reachingcenterline

CONF Phase type (1000 for pressure calibration, 2000for thermal calibration, 3000 for materialevaluation)

CP Pressure coefficient

CST Central Standard Time

D3, db Sound pressure level of the root mean squareacoustic pressure, decibel

'S DC Tunnel event indication of the closing of the tunnelfairing doors

DO Tunnel event indication of the opening of thetunnel fairing doors

K .Gardon gage output, mv

EVENT,CANERA Indication of tunnel injection sequence (DO, LO, CL,DC, OCL) and camera firings (SHG, IR)

f/nz IR camera f stop setting xx

FLANGE Static pressure measured on the Aerothermal nozzleexit flange, psia

GAGE NO.,Ti Gardon gage identification number

I(TT), H(RTT), Heat transfer coefficient based on TT, RTT orH(O.915TT) 0.915T i.e., H(RTT) - QDOT/(RTT-TW),

Btu/ft -sec-*F

IR Camera firing indication for infrared color monitor

camera

Ki, Kulite No. Kulite gage identification number

KG Gardon gage temperature calibration factor, *F/mv

5.3

.5% .V . 5.'5 VV V ,' .. ,.... * . .. * ,

LO Tunnel event indication of the lift-off of themodel in the tank

M Free-stream Mach number

U Dynamic vi cosity based on free-stream temperature,

lbf-sec/ft

OCL Tunnel event indication of the model leaving

centerline

P,PIN Free-stream static pressure, psia

PIC NO. Photograph number for each camera and each run

POD ANGLE Angular rotation of the OHS Pod contour about itsleading edge; positive being trailing edge down,deg

PT Tunnel stilling chamber pressure, psia

SPW Surface static pressure, psia

Q Free-stream dynamic pressure, psfa

QDOT Measured heat-transfer rate, Btu/ft2-sec

R Multiplier on total temperature

R Free-stream unit Reynolds number, ft- 1

RHO Free-stream density, lbm/ft3

RMS Root mean square acoustic pressure, psia

RTT Relationship for recovery temperature, product ofa multiplier, R, and the total temperature, TT, *F

* RUN Data set identification number

SAMPLE Sample identification letter

* SG Camera firing indication for shadovgraph camera

di. ST(TT), ST(RTT), Stanton number based on TT, RTT, or 0.195TT; i.e.;ST(O.915TT)

ST(RTT) - H(RTT)/[RHO*V*(0.2235 + 1.35 x 10- 5 (RTT + TW)]

T Free-stream static temperature, *Fd

TAP, STATIC NO. Static tap identification number

v TTGE Gardon gage edge temperature, 'F..,I,A

. V 71 -. - - ........ a

T.DEL Temperature differential from the center to the.4 aedge of the Gardon gage disc, *F

TIME Elapsed time from start of wedge injection(lift-off), sec

TIMECL Time at which the wedge reached tunnel centerline,

Central Standard Time or sec

TIMEEXP Time of exposure to the tunnel flow when the data

were recorded, [TIME - (32/57)(TIMEINJ)], sec

] ~TIMEINJ Time of model injection; elapsed time from lift-offto arrival at tunnel centerline, sec

TIMERD Time from lift-off at which Gardon gage datawere reduced, sec

TKi Temperature measurevent from a thermocouplelocated near the it Kulite gage, *F

TP Wedge cavity thermocouple temperature, °F

TPTi Temperature measurement from a thermocouple locatedon the ith ESP pressure module, *F

TSi Thermal model surface, i - 1 to 13,and backside thermocouple, i - 14 to 16; Samplebackside thermocouple, i - 1 to 3, oF

TT Tunnel stilling chamber temperature, *F

TW Gage surface temperature, *F

V Free-stream velocity, ft/sec

WA, WEDGE ANGLE Wedge angle, deg (see Fig. 4)

,4 ,. . I, Y, Z Orthogonal body axis system directions(see Fig. 4 and 5)

. C Sample emissivity

",..

V~*

W~ W~ L T~ E ~-'! W U* U o -. o... . . .

1.0 INTRODUCTION

The work reported herein was performed by the Arnold EngineeringDevelopment Center (AEDC), Air Force Systems Command (AFSC), under

Program Element 921E01, Control Number 9EO1, at the request of the

National Aeronautics and Space Administration (NASA/JSC), Houston, TX.

The NASA project manager was Mr. Jack Barneburg and the Rockwell

International (RI) project engineer was Mr. Paul Lemoine. The resultswere obtained by Calspan Field Services, Inc./AEDC Division, operatingcontractor for the Aerospace Flight Dynamics testing effort at the AEDC,AFSC, Arnold Air Force Station, Tennessee. The tests were performed in

0the von Karman Gas Dynamics Facility (VKF), Aerothermal Wind Tunnel

(C), on May 27, August 8 and 11, 1983 under AEDC Project No. CA76VC(Calspan No. V41C-3E).

During the sixth flight of the Space Shuttle, portions of the

Advanced Flexible Reusable Surface Insulation (AFRSI) on the OrbitalManeuvering System (OMS) Pod failed. The objective of this test programwas to investigate the thermostructural performance of the AFRSI underaeroheating conditions to help interpret the physical mechanism by whichthe failure was incurred.

In order to simulate the aerodynamic environment in which the STS-6

failure occurred, and therefore duplicate the failure in the tunnel,* various flow requirements were identified. To investigate the degree to

which these flow characteristics could be achieved using the proposedtest article, a Feasibility Checkout Phase was performed in a separatetunnel entry. The principal objective of this feasibility study was tomaintain and control a turbulent boundary layer separation upstream of

the proposed AFRSI location at the low Reynolds number desired forspecific flight simulation.

- The second tunnel entry began with a Calibration Phase intended toestablish the testing environment in terms of static and acousticpressure distributions and aerodynamic heating levels. The equilibriumtemperature of the surface of the insulation material was alsodetermined. The test was completed with the evaluation of 3 AFRSI test

samples at total pressures of 20 and 25 psia and total temperaturesranging up to 1115F.

Inquiries to obtain copies of the test data should be directedto NASA/JSC/ES2, Houston, TX 77058. A microfilm record of the tab-ulated data has been retained at AEDC.

2.0 APPARATUS

2.1 TEST FACILITY

The Mach 4 Aerothermal Tunnel (C) is a closed-circuit, high

temperature, supersonic freejet wind tunnel with an axisymmetriccontoured nozzle and a 25 in.-diam nozzle exit, Fig. 1. This tunnel

utilizes parts of the Tunnel C circuit (the electric air heater, the.- Tunnel C test section and injection system) and operates continuously19

K,. : ....:.

• . -s- 7

over a range of pressures from nominally 15 psia at a minimum stagnationtemperature of 250*F to 180 psia at a stagnation temperature of 1110"F.Using the normal Tunnel C Mach 10 circuit (Series Heater Circuit), theAerothermal Mach 4 nozzle operates at a maximum pressure and temperatureof 100 psia and 1440*F, respectively. The air temperatures andpressures are normally achieved by mixing high temperature air (up to1790*F) from the primary flow discharged from the electric heater with

the bypass air flow (at 980*F) from the natural gas-fired heater. Theprimary and the bypass air flows discharge into a mixing chamber justupstream of the Aerothermal Tunnel C stilling chamber. The entireAerothermal nozzle insert (the mixing chamber, throat and nozzlesections) is water cooled by integral, external water jackets. Sincethe test unit utilizes the Tunnel C model injection system, it allowsfor the removal of the model from the test section while the freejettunnel remains in operation. A description of the Tunnel C equipmentmay be found in Ref. 1.

2.2 TEST ARTICLE

The standard Aerotherm Materials Wedge, used for all phases of thistest in Tunnel C, is a 12 inch wide by 34 inch long water-cooled flatplate with a backstep 14 inches from the leading edge for materialsample installation. The installation of this wedge for the FeasibilityCheckout Entry is shown in Fig. 2. The wedge was modified to includelateral extensions upstream of the backstep to reduce any edge effectson the material sample. This is depicted in Fig. 3 and characterized inthe sketch of Fig. 4. The wedge was instrumented with Gardon-type heatgages to measure the local wedge heating environment, and the locations

of these gages are given in Table 1.

Duplicating the OMS Pod geometry for the test models was a primaryI ~simulation requirement. A portion of the actual contour of the pod atthe location of the flight failure was used to develop a two-dimensionalrepresentation for these test needs. For the feasibility study, a 0.13-scale model, referred to as contour 1 and depicted in Fig. 5, wasfabricated from wood and covered with a thin ceramic layer. This shaperepresented the foremost edge of the OMS Pod up to and including thearea of failure. A second wooden model tested was similar to contour 1,except that it had been reduced in size to investigate thecontrollability of the separation characteristics.

The installation of the wedge for the Calibration and MaterialEvaluation Phases is shown in Fig. 6. The sketch in Fig. 7 illustratesthe locations of the extensive instrumentation installed for the

. calibrations including Gardon gages, Kulite acoustic pressure gages, andsurface static pressure ports. The locations of the static pressure tapsand Kulite acoustic sensors are given in Tables 2 and 3, respectively.

For the calibration models and material samples, a 0.20-scalecontour o the OMS Pod was used. This shape is depicted in Fig. 8 and aahulat' ,t of the contour coordinates is given in Table 4. The pressure

if",bo.r, -hown in Fig. 9, was constructed of 1020 mild steel. The modelba,.; 32 flush orifice pressure taps on the contour surface and 24 Kulitetransducers installed adjacent to selected tap positions, located as

ONi tabulated in Tables 2 and 3.

7

.N N-kr1W1 W1. - 7-3 W3 * P-O 0 *-F. F - * -. 0 -. P.

The thermal model, shown in Fig. 10, was constructed of Low-9 temperature Reusable Surface Insulation (LRSI) tile material in the same

shape as the pressure model. The model had 13 Chromel*-AlumelOthermocouples located very near the LRSI surface in the location shownin Fig. lOb and tabulated in Table 5. Also, three thermocouples were~installed on the backside of the LRSI material.

The mounting hardware for all test models was built with the. ,N capability to rotate the entire contoured shape about its leading edge.

This provided additional control of the boundary layer separationcharacteristics and the OMS Pod surface environment. The configuration

chosen for all calibration and sample tests was with the pod reclined 8deg down. The instrumentation locations tabulated and all modelsketches are representative of that configuration.

Three AFRSI test samples were conformed to the selected contour andbonded similar to the actual flight installation. A typical sample isshown in Fig. 11, prior to its evaluation. The samples are identifiedin Table 6, as characterized by the conditioning each underwent beforetesting. As shown in the photograph, the samples were attached using 17bolts in a Silfrax* border around the AFRSL. The bolt holes were thenplugged with uncoated LRSI material to provide a smooth surface. Eachsample had three Chromel-Alumel thermocouples installed on itsundersurface.

To insure a turbulent boundary layer along the wedge surface,boundary layer trips were installed one inch downstream of the wedgeleading edge. The trip balls were 0.093 inches in diameter and were4 iarranged in a three-row configuration, as shown in Fig. 4.

Poettest photographs of the thermal body and the AFRSI samples areshown in Fig. 12.

2.3 TEST INSTRUMENTATION

The instrumentation, recording devices, and calibration methodsused to measure the primary tunnel and test data parameters are listedin Table 7a along with the estimated measurement uncertainties. The

€J% range and estimated uncertainties for primary parameters that werecalculated from the measured parameters are listed in Table 7b.

.. To define the convective heating environment experienced by thematerial specimens, Gardon-type heat transfer gages were mounted in thewedge surface upstream of the OMS body, as shown in Fig. 4. Heat-transfer rate measurements were obtained with high-temperature Gardongages which were supplied and calibrated by the AEDC. The gages were0.25-in. in diameter with a sensing foil thickness of 0.010-in. Theywere instrumented with Chromel-Alumel thermocouples which provided thegage edge temperature measurement. Gage edge temperatures, together withthe sensing foil thermocouple output, were used to determine the gagesurface temperatures and corresponding gage heat-transfer rate. Thesedata were then used to compute the local heat-transfer coefficient andStanton number.

esN

°-

The model surface static pressures were measured with two PressureSystems Incorporated* Model ESP-32 pressure modules with a range of +15paid. The ESP-32 pressure sensor module has 32 ports with a siliconpressure transducer per port that can be digitally addressed andI calibrated on line. The ESP-32 modules were installed inside the OMSPod -contour in close proximity to the static taps, thus reducing thepressure stabilization time required. The static pressures weremeasured only during the second entry.

The surface dynamic pressure levels were measured with RI-suppliedand installed Kulite sensors and transducers. These dynamic signalswere recorded on multi-track tape recorders for user analysis. Selectedchannels (15) were routed to AEDC rms meters which were incorporated inthe data acquisition system.

Several Chromel-Alumel thermocouples were used on the various testmodels to monitor critical model temperatures. The pressure model had

.% thermocouples near Kulite gages 105, 110, 114, 116 and 124, monitored top. ~'insure they did not overheat and fail. The thermal model had 13 surface

thermocouples to measure its surface equilibrium temperature, and thesewere located as shown in Fig. 10b and tabulated in Table 5. All AFRSItest samples and the thermal model had 3 thermocouples on the backsideof the insulation to monitor the support structure temperature. Thewedge cavity, where all the gage lead wires were routed, and both ESPmodules were instrumented to monitor operating temperatures in theseareas.

The infrared system which was used to measure model surfacetemperatures utilizes an AGA* Thermovision 680 camera which scans at arate of 16 frames per second. The camera has a detector which issensitive to infrared radiation in the 2 to 6 micron wavelength band. Adescription of the system is given in Ref. 2.

A total time of exposure to the tunnel flow is required for datareduction. All the events which occur during a run are timed using thedigital clock in the DEC-10 computer, which processes all data from thecontinuous tunnels.

A variety of cameras was used to record the response of thematerials to the tunnel environment. The cameras, frame rates and film

,. -identifications are summarized in Table 8. A plumb line was attached to" V the aft window to provide a vertical reference in the shadowgraph

stills.

.'.7.Z

. ..

-.,

. .

.. 9

3.0 TEST DESCRIPTION

93.1 TEST CONDITIONS

The nominal free stream test conditions are given below.

M PT, psia TT, OF QpsfaI4 20 350 225

840 220f,1440 21425 340 281

1440 27030 330 336

1440 32060 1440 641

A test summary showing a detailed account of all runs of each phaseis presented in Table 9.

3.2 TEST PROCEDURES

In the VKF continuous flow wind tunnels (A, B, C), the model ismounted on a sting support mechanism in an installation tank directlyunderneath the tunnel test section. The tank is separated from thetunnel by a pair of fairing doors and a safety door. When closed, thefairing doors, except for a slot for the pitch sector, cover the openingto the tank and the safety door seals the tunnel from the tank area.After the model is prepared for a data run, the personnel access door tothe installation tank is closed, the tank is vented to the tunnel flow,the safety and fairing doors are opened, and the model is injected intothe airstream. After the data are obtained, the model is retracted intothe tank and the sequence is reversed with the tank being vented toatmosphere to allow access to the model in preparation for the next run.A given injection cycle is termed a run, and all the data obtained areidentified in the data tabulations by a run number.

The standard AEDC materials wedge testing technique was used tosupport the calibration bodies and material samples and provide thedesired local flow condition. A detailed description of this technique

'may be found in Ref. 3.

.',Instrumentation outputs were recorded using the digital datascanner in conjunction with the analog subsystem. Data acquisition from

all instruments other than the infrared camera was under the control ofa Digital Equipment Corporation (DEC) PDP 11/40 computer, utilizing therandom access data system (RADS). The data system was started prior toinjection, while the model was still in the tank. All the transduceroutputs were recorded at the rate specified in Table 10. Additionalloops of data were recorded each time the sequence cameras were

Mtriggered, thereby providing a time point for each photograph. The datawere transmitted to a DEC-10 computer for processing.

10

.J

The infrared system operates independently of the RADS. During a

run the AGA 680 infrared camera scanned the model to produce a completepicture at the rate of 16 frames per second. The camera output wasrecorded on analog tape and simultaneously displayed on a colortelevision monitor. The developing color patterns were observed as themodel surface temperature increased, and the monitor was photographed asdescribed in Table 10 to provide a permanent record. The camera outputwas also fed to an analog-to-digital converter under the control of aPDP 11/34 computer. Every 4 seconds a single frame was digitized andtransmitted to the DEC-10 computer. An additional loop of data from theRADS system was recorded each time a frame was digitized to provide arecord of test conditions at the time infrared data were obtained.

Characteristics of the data acquisition peculiar to each test phasewill be described individually.

3.2.1 Feasibility Checkout Phase

" To determine the flow separation and reattachment characteristicsof the proposed OHS Pod contour, several runs of oil flow visualizationwere obtained at several free stream pressures. The wedge and wooden

" contoured models were painted with a high-temperature black paint justprior to the application of the white oil. The oil was applied with asponge to provide a sheet of oil over the entire surface. The model wasinjected at the desired wedge angle and remained on centerline for atleast 5 seconds. During the exposure, views of the oil flow progression

were videotaped from the top window port and the forward side window. Atypical frame of the tape from the top view is shown in Fig. 13. Also,the shadowgraph system was videotaped and helped qualify the flow on thewedge and OHS Pod model.

Heat transfer measurements were taken on the wedge to define theconvective heating environment in the area upstream of the wooden

contour.

3.2.2 Pressure Calibration Phase

The flow environment on the test article and the wedge plate wasA extensively measured at many model attitudes and flow conditions to

quantify these parameters for the material evaluations. The pressurecalibration body, instrumented for static and dynamic pressuremeasurements, was installed on the aerotherm wedge for this phase.

The injection data-taking sequence was initiated by positioning the* wedge at the desired wedge angle and beginning the tape recording of the

SCL Kulite transducer outputs. After several seconds, the tunnel doors wereopened, the model was injected to the tunnel centerline and the doorswere closed. After nominally 20 seconds on centerline, the doors were

• .opened, the model was retracted, the tape recorders were stopped and thedata-taking sequence was completed. For the shorter calibration runs,nominally 6 seconds on centerline, the doors were left open throughout.

" While on centerline, the convective heat transfer environment, thestatic pressure distribution and selected rms pressure levels weredetermined. Also, shadowgraph still photographs recorded the shock wavepattern and general TV coverage was videotaped..11

I 3.2.3 Thermal Calibration PhaseTo quantify the surface equilibrium temperature expected on the

AFRSI samples, the thermal model was installed on the wedge and injectedinto the tunnel for an extended period of time. Several of the surfacethermocouples were monitored during the run to determine when the LRSIhad reached an equilibrium temperature. Starting at the maximum tunneltotal temperature, 1440*F, four runs of thermal calibrations wereachieved until a desired maximum surface equilibrium temperature wasobtained. Infrared data were also obtained on the thermal modelsurface. Also, low and high speed movie coverage of the LRSI wasrecorded for the approximate 4 minute tunnel exposure.

3.2.4 Material Evaluation Phase

AFRSI test samples A, B and F were evaluated in the tunnel. Thetest article was positioned at the desired wedge angle and the data-taking sequence was initiated at lift-off from the tank.

The samples remained on centerline nominally 250 seconds, or untila failure was incurred. The convective heat transfer environment andthe static pressure distribution on the wedge were determined. Theinfrared camera was continuously updating the sample surfacetemperature, and movies and still photographs were taken of the color IRmonitor. Movies of the sample were taken starting at lift-off. Highspeed movies were initiated when the failure was first beginning and thephysical apearance of the sample first changed.

U 3.3 DATA REDUCTIONMeasured stilling chamber pressure and temperature and the

calibrated test section Mach number were used to compute the free-streamparameters. The equations for a perfect gas isentropic expansion from

* stilling chamber to test section were modified to account for real gaseffects.

Data measurements obtained from the Gardon gages are gage output(E) and gage edge temperature (TGE). The gages are direct reading heatflux transducers and the gage output is converted to heating rate bymeans of a laboratory calibrated scale factor (CI). The scale factorhas been found to be a function of gage temperature and, therefore, mustbe corrected for gage temperature changes,

C2 - Cl f(TGE) (1)

Heat flux to the gage is then calculated for each data point by thefollowing equation:

QDOT - (C2)(z) (2)

• 'The gage wall temperature used in computing the gage heat-transfercoefficient is obtained from two measurements - the output of the gageedge thermocouple (TGE) and the temperature difference (TGDEL) from the

12

* ** * .. * *. ... - - % %** 'a ~. %* * %.%*g ~'*

.w - ° ~ ~ . _ ~ -

gage center to its edge. The measured values used in the reduction*: equations were filtrced using 4 consecutive data points taken within

less than a half a second, and typically just one second aftercenterline. TGDEL is proportional to .he gage output, E, and is

3 calculated by:TGDEL - (KG)(E) (3)

o The gage wall temperature is then computed as

TW - TGE + 0.75 TGDEL (4)

. where the factor 0.75 represents the average, or integrated, valueacross the gage.

The heat transfer coefficient for each gage was computed using thefollowing equation

1(177) _- (5)* TRTT-TWJ

where QDOT and TW were obtained from gage measurements. The product RTTrepresents the recovery temperature, which is not known at eachmeasurement location. H(RTT) was calculated for values of R of 1.0 and0.915.

The heat transfer coefficient was then converted to Stanton number* by:

(T(TT) - 1(1TT) *(l mO)(V)[0.2235 + 1.35 x 10- 5 (RTT + TV)]

Prior to each operational shift, the two ESP-32 modules with atotal of 64, t15 psid transducers were calibrated. From these data,scale factors for each transducer were calculated. Prior to each testrun the modules were referenced to a hard vacuum to obtain zero readingsfor each transducer. The appropriate scale factor and zero reading wereused to determine the pressure on each transducer. Five consecutivereadings, taken within a half a second, were averaged to obtain thestatic pressure. The readings were obtained when the tunnel doors wereclosed, exce for the shorter calibration runs, and the model was oncenterlir i ?s was nominally 10-20 seconds after centerline wasreached. A -. - coefficient, CP, was also calculated from:

CP - 144 (PW-P)

The rms pressure measurements were obtained by sampling the ruemeter output and multiplying this output by the user-suppliedsensitivity factors. These were related to decibel level by:

13

[ " .

-. -. . . -. .. . . . ".". ., - ._ . % ' . *,. . " -. '" - .•. ,'. ',, -.. ,. . ." ' " - -:

RMSdb - 20 loglO 2 0-

2.9 x 1-

As discussed in Section 3.2, the output of the IR camera isdisplayed in real time on a color television monitor. A 70mm camera wasused to photograph the monitor screen simultaneously with a single frame

. digitizing process. An example of a monitor screen photograph is givenin Fig. 14. On the television monitor the temperature range, which thesystem is set up to measure, is divided, in a nonlinear fashion, into

4ten separate colors, starting with blue for the lowest temperature andprogressing through white for the highest. Each color then represents atemperature band within the total range, and the interface between twocolors corresponds to one particular temperature. This provides a viewin which unusual temperature patterns would be more easily discernedthan in the digital data tabulations.

As noted in Section 3.2, digital infrared data were obtained at theC' rate of one frame every four seconds. One complete frame of infrared

data consists of 70 scan lines with 110 points per line for a total of7700 discrete but overlapping spots. For most test installations thefield of view is such that the model does not fill the complete frame.In order to save storage space in the computer, only the portion of theframe which contains good model data is digitized. For the AFRSI andLRSI test articles, a typical area of interest (see Fig. 14) wasapproximately 80 lines by 70 points (5600 discrete spots). For eachspot, the camera output is digitized and converted to a temperaturereading by means of an equation derived from basic laws of radiation andincorporating various constants peculiar to this system. These

constants are obtained from laboratory calibrations using a. standardblack body source.

The temperature calculations were carried out using surfaceemissivity values determined from AEDC reflectivity measurements made atroom temperature. A monochromatic light source was used to illuminatethe material sample. The hemispherical spectral reflectivity was thenmeasured. Assuming the sample is opaque to radiation at each discretewavelength at which reflectivity was measured, and assuming that thematerial acts as a diffuse-gray surface, the emissivity (M) wasdetermined from the reflectivity as follows:

.p.

- 1 - REFLECTIVITY

This reflectivity measurement was made at several wavelengths. Theemissivity values for each wavelength were weighed by the responsecharacteristic of the IR camera detector at that wavelength, and the

p. . result integrated over the total wavelength range of the IR detector toprovide a value of total emissivity. Emissivity values of 0.82 for theLRSI tile (thermal model) and 0.68 for the AFRSI were thus determined.

14

'.5,

. . •- .-. . • • . . .

Note that hemispherical reflectivity measurements were used to-

.evaluate emissivity. Therefore, strictly speaking, the emissivity,*:..* calculated above is the hemispherical emissivity for an opaque surface.

*A reasonable approximation (within 2 to 5 percent) for gray-body diffuseemitters is that the directional emissivity is equal to thehemispherical emissivity for surface angles within 40 degrees of thenormal. Therefore, the temperature data produced from IR measurementsduring this test are valid only for surfaces aligned within 40 degrees

K-" of horizontal.

The calculated temperatures were tabulated in a two-dimensionalarray in which each spot location is defined by its Line number andPoint number. In order to use the IR data, it is necessary to define the

model position in terms of Line and Point number. This was done by

taking wind-off infrared scans of the wedge, with a specimen attached,in the tunnel at the test attitude. A wire was positioned along theedge of the specimen, and an external electrical current was proviedcausing the wire to heat up. Thus, it was possible to locate thespecimen on the IR video monitor via the outline produced by the hotwire. A marker is then superimposed on the video monitor by the IRsystem electronics. This marker is a matrix of dots representing eachspot in the digitized IR data. The marker can be controlled so that

individual Lines or Points may be identified. In this manner the Linesand Points corresponding to the sample location were defined. Figure 14

S.identifies the location, in terms of Lines and Points, of several pointsSof interest. The actual field digitized covered the range of all of

these points, so that the field did not have to be changed during the

-test.

, 1The spot size is a function of the camera detector size, the camera

optics, and the distance to the test article. However, it must beemphasized that each IR "spot" was about 0.35 in. in diameter and thatthe measured radiation from this size spot is used to calculate thesurface temperature. Also, note that this spot is for a surface normalto the IR camera (i.e., in the horizontal plane). Measurements on

.. surfaces inclined relative to the camera will be influenced by model

1 temperatures over an area larger than this spot size.

" 3.4 UNCERTAINTY OF MEASUREMENTS

In general, instrumentation calibrations and data uncertaintyestimates were made using methods recognized by the National Bureau of

% Standards (NBS). Measurement uncertainty is a combination of bias andprecision errors defined as:

U +(B + t95s)

where B is the bias limit, S is the sample standard deviation and t95is the 95th percentile point for the two-tailed Student's "t" distribu-tion (95-percent confidence interval), which for sample sizes greater

than 30 is taken equal to 2.

15

"--....-** { ¢f ;: ¢ . . .{ ,= - :..y , '. " * - ". . " " • .-:~.'.-"-'- .. . - . -.

Estimates of the measured data uncertainties for this test aregiven in Table 7a. The data uncertainties for the measurements aredetermined from in-place calibrations through the data recording systemand data reduction program.

Propagation of the bias and precision errors of measured datathrough the calculated data was made in accordance with Ref. 4 and theresults are given in Table 7b.

4.0 DATA PACKAGE PRESENTATION

A sample data tabulation is presented in Appendix III. Included isa tabulation of the heat-transfer data for the feasibility study. Forthe pressure calibrations, samples of the heat transfer data, the staticpressure data, the rms pressure data and the thermocouple data areincluded. For the thermal calibrations, samples of the heat transferdata, the static pressure data, the surface thermocouple data and an IRtabulation are included. For the material evaluation phase, samples ofthe heat transfer data, static pressure data, sample thermocouple dataand an IR tabulation are included.

A' %

." o

• 9'

Po

?,I', %; ,'' ' X '-' %' '."': "-'"." "",.-." "." "-"'.- "'"."..2 "'."-'..'.'.'.

2..'..'..'..'-.'.:'..'.""."".-.. .."."."" '- '-'

.. *.9*

Jij

~~ '1. Test Facilities Handbook (Eleventh Edition), "von Karman GasDynamics Facility, Vol. 3," Arnold Engineering Development Center,April 1981.

2. Boylan, D. E. Carver, D. B., Stallings, D. W., and Trimmer, L. L."Measurement and Mapping of Aerodynamic Heating Using a Remote

Infrared Scanning Camera in Continuous Flow Wind Tunnels," AIAAPreprint 78-799, April 1978.

3. Matthews, R. K. and Stallings, D. W. "Materials Testing in the VKFContinuous Flow Wind Tunnels," AIAA 9th Aerodynamic Testing

Ii " Conference, Arlington, TX, June 7-9, 1976.

4. Thompson, J. W. and Abernethy, R. B. et al. "Handbook Uncertaintyin Gas Turbine Measurements," AEDC-TR-73-5 (AD755356), February1973.

A::

A.

-"'

.17

% %

*.. ;APPENDIX I

ILLUSTRATIONS

-..

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I.

"*

18

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. , .•"A

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,"""""

" > "

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14

)I. SI'PP(HT

AERO)THERMAL I N.J1 UTV IkfETHA('TI ON

AIING CHAMBER NSF

ELCRC TT-

is --- 0 A O) I, I NS

7AI SUPPL FEEI//II

/GAS-HEATED BAFFLES AND SCREENS %511 (0.N

a. Tunnel assembly

MODEL INSPECTION DIFFUSERUPHOTOGRAPHY WINDOWS DISCHARGE%

MIXTRANSDUMERS

MOEDINELTO

TANPITHRANSER

ENTANC AN ALE

DOO

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BYPASS

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00

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0 w0

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.0 co0) 4.Ooil CA- S.. 60 0

iq * 00f' 0.23

Top View

I ILI Contour 1* (0.13 scale)i " "X=. Z in.o 00.155 0.3620. 554 1. 0690.788 1.375

1.304 1.933

19.6 2.566 2.9053.305 3.3524.204 3.8065.265 4.2496.536 4.675

8.042 5.100

S.Contour

5r 2

-* r/

1.-08.0

-4.

• Note: Contour 2 was qht.ainod by rotating the identical contour

downward as shown above.

Figure 5. Feasibility Test Models

2)4

p" p

,*.,; 5 Sr.wY

.,,V..",% '''" '' .,,,. , . .".e '" ."-•'""""'.,.---.' '. '. - - . , ,-"-"-'-"-'-

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STS

1 2 thru P 10 11 12 13

,' Bordering %Insulation See Table 6 for

"i ::: ;Materials thermocouple locations.

'S

*% %

" 2 b. Thermal Calibration Model Instrumentation5Figure 10. Concluded

.33

LRSI T1l

- - C'- - - -..-- A. -.- -

I

I

*-4

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CORRIAI ION I

345 1054

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+--- 353 1000

330 924

.- 300 843I R CAM ERA.4 F IELD O F V IE W 45 69

~- 245 693

f/i.8 fM1O

LEFT SIDE L)00KING DOWNSTREAM TOP VIEW INTERFA(E

Sample Leadld g Edge TEMPERATtlFS. - F

Ou~utline If Th 'r* [

r., 14 lnt

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" k,.-Itned Contour

S-- . IR Data Tahulation, Sampl,

,4.4P014T IN

q J*IN .vW I R16 17 18 19 2. 21 '

"i AL.PHA, - 4,) 6:1 8" 7 1 100 1(11'e'

1' ~ I nr %- -

Figure 14. Spatial Correlation of Digitized IR Data withCamera Field of View and Test Article

i4

,n. in.m

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in ..

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Table 1. Gardon Heat Gage Locations

. Gage No.* X Y

1 13.5 4.502 3.10

3 1.80

4 7.5 0

- . 5 9.0

6 10.5

7 12.0

8 13.5, : 9 -1.80

10 -3.10

11 1-4.50r.

."0

*Note: For the Feasibility Checkout Phase, these gages

were referred to as T1 through TIl.

' . .

at 2-, ..:

',:..: ..:

.O'4 S1

-.'; 42

a; :.

*71

Table 2. Static Pressure Tap Locationsa. Wedge Taps

.1*

TAP X Y TAP X Y

1 10.5 2.5 11 11.5 0.25

2 12.0 / 12 12.0

' k 3 13.5 13 12.54 14.5 14 13.0

~*~;5 15.25 15 13.5

6 7.0 0.25 16 14.25

7 8.0 17 14.5

8 9.0 18 15.0

9 10.0 19 15.25

" -10 11.0

-43

•.. ..?.*

.1' *g. 43

0 ,, . .- ;".- ' '? ..,;.,4 .... ..- .: ?.... -.';'::;:. :i. i:",,, '- - .'-'-,.'--. ...-:::,.. : ,.,

,

p"

Table 2. Concluded

-_ b. Pressure Calibration Panel Taps

Tap X Y Z Tap X Y Z

101 16.68 6.5 1.61 117 18.63 0.25 3.16

102 17.80 6.5 2.60 118 19.07 0.25 3.40

103 19.07 6.5 3.40 119 19.51 0.25 3.63

104 16.68 5.5 1.61 120 19.97 0.25 3.84

105 17.80 5.5 2.60 121 20.42 0.25 4.05

106 16.68 4.5 1.61 122 20.88 0.25 4.24

107 16.68 2.5 1.61 123 21.35 0.25 4.42

108 19.07 2.5 3.40 124 21.82 0.25 4.60

* 109 15.76 0.25 0.43 125 22.76 0.25 4.92

110 16.05 0.25 0.84 126 16.68 -2.5 1.61

111 16.35 0.25 1.23 127 19.07 -2.5 3.40

112 16.68 0.25 1.61 128 16.68 -4.5 1.61

. 113 17.03 0.25 1.96 129 19.07 -4.5 3.40

114 17.41 0.25 2.29 130 16.68 -5.5 1.61

115 17.80 0.25 2.60 131 16.68 -6.5 1.61

-.. 116 18.21 0.25 2.89 132 19.07 -6.5 3.40

9. _..44

i

N-

-°.- *

L4.'.,

Table 3. Kulite Dynamic Pressure Gage Locations

5Wedge Kulite Gages

Kulite X Y

1 10.5 2.25

2 12.0

V. 3 13.5

- 4 14.5

5 15.25

6 7.0 0

8 8.75

9 10.0

10 11.0

12 11.75

14 13.0

17 15.0

19 15.25

.' ., Pressure Calibration Panel Kulite Gages

p Kulite X Y Z Kulite X Y Z101 16.68 6.25 1.61 118 19.07 0 3.40

. 102 17.80 6.25 2.60 120 19.97 0 3.84

.% 103 19.07 6.25 3.40 122 20.88 0 4.24

104 16.68 5.25 1.61 124 21.82 0 4.60

. 105 17.80 5.25 2.60 125 22.76 0 4.92

106 16.68 4.25 1.61 126 16.68 -2.25 1.61

" 107 16.68 2.25 1.61 127 19.07 -2.25 3.40

108 19.07 2.25 3.40 128 16.68 -4.25 1.61

110 16.05 0 0.84 129 19.07 -4.25 3.40

112 16.68 0 1.61 130 16.68 -5.25 1.61

114 17.41 0 2.29 131 16.68 -6.25 1.61

4 116 18.21 0 2.89 132 19.07 -6.25 3.40

45

1._,,¢.,'o % -",, ; . "' _. .. , . -.- '_.", .,"-"- . ""% . " " -. ' ' . 'L .•., ."-•,. "•",. _. . -- % '_,,' ,'. ". ,

%:' Table 4. Coordinates of 0.2-Scale PartialOMS Pod ContourN

X,in. Z, in.0 O0 0

0.0975 0.2625

0.2391 0.5574

0.3747 0.8052

0.5310 1.1181

0.6846 1.3776

0.8529 1.6284

1.0329 1.8879

1.2129 2.1150

1.4193 2.3598

1.6170 2.5782

1.8177 2.7846

2.0064 2.9736

2.5317 3.4365

2.9361 3.7611

3.2724 3.9972

3.6294 4.2627

3.9480 4.4691

4.2489 4.6785

4.6266 4.8969'4%

5. 0841 5.1564

5.4765 5.3748

5.9898 5.6226

6.4680 5.8554

7.2204 6 .1860

Note: See Fig. 8 for definition of contour coordinates.46

.1.•

46 "

;U., . . . r r . , . , , ,- , . , . .' j ; - .. . .. ' . , .

U1

Table 5. Thermal Model Surface Thermocouple Locations

* : T/C No. x Y Z

1 15.90 0 0.63

* 2 16.52 1.42

3 16.86 1.79

-.4 17.22 2.13

5 17.60 2.45

6 18.00 2.75

7 18.42 3.03

h 8 18.85 3.28

9 19.29 3.52

1.. 10 19.74 3.74

11 20.65 4.15

12 21.58 4.51

13 22.53 4.84

Table 6. AFRSI Sample Descriptions

Sample No. Description

A Baseline (1-inch stitching)

B Baseline thermally conditioned (TC) to 1100*F

F STS-6 blanket (panel removed after STS-6v _mission)

" (4

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Table 9. Test Summarya. Feasibility Checkout Phase

.4'

RUN OMS POD MODEL PT,psia TT,F WA,deg

1001 None 30 1440 0

1002 -2

1003 -4

1004 -6

1005 0

1006

1007 60

1008 20

1009

1010* Contour 1

1011* Contour 1 60

1012* Contour 2 - Reclined 20

1013* Contour 2 - Reclined 30

1014* Contour 1

1015 None

• Oil flow runs

52" P_

Table 9. Continued

b. Calibration Phase

RUN PT,psia TT,*F WA,deg TIME ON CENTERLINE(approx.),sec

2 30 318 0 143 329 0 11

4 254 0 28

- 5 301 -4 23

6 25 318 0 29

9 340 -2 22

11 20 347 -4 23

12 349 -2 22

13 840 0 31

14 -4 23

15 -2 25

17 1440 -4 7

18 -2 9

19 -0 8

20 25 1420 0 8

' 21 1440 -4 9

* 22 -2 8

,4 .

i--

r ".4

53p .-

!-"' |

-'.: .'.'.." ... '. , . '... ,..'.'. .. . . " i':"""" "" -"/ -" """-'"" '" "" " "" """" " " " " """;" " " " " " "" "" "

Table 9. Concludedc. Material Evaluation Phase

RUN PT,psia TT,°F WA,deg SAMPLE EXPOSURE TIME* ~.(approx.),sec

23 20 180* -2 A - Baseline 250

24 25 313 -2 A - Baseline 250

25 20 1440 0 Thermal Calibration Model 250

S26 1315 j93&r , 27 1215 250

28 25 1215 1 250

"- 29 20 1115 B-Baseline TC to 100°F 94

30 20 975 F-STS-6 Blanket 106* 'C

R * The total temperature climbed approximately 6°F/minute throughoutthis run, and TT = 204*F at the time of model retraction.

-5

,,

. 1 . . . . .*°* * . .... % . .,-- t"'-.

Table 10. Summary of Data Acquisition and Tabular Print

Gardon Gage Data

3 Data Acquisition Approx. every 0.1 sec F(data taking rate)

Tabular Printed Data Data at 1 sec after centerline.Magnetic Tape All recorded data

Thermocouple Data

' Data Acquisition Approx. every 0.1 sec for first 15 sec(data taking rate) of run, then once every 2 sec (calibration) -

or 4 sec (Mat'l Evaluation)

Tabular Printed Data Once every 2 sec (Calib.) or 4 sec(Mat'l Eval.) and also at camera firings

Magnetic Tape All recorded data

Static Pressure Data

- Data Acquisition Same as for thermocouples* (data taking rate)

Tabular Printed Data Data averaged over 5 consecutive readings10-15 seconds after centerline as indicatedon data

Magnetic Tape All recorded data

Dynamic Pressure Data

Data Acquisition Continuously recorded on magnetic tape.RMS meter data read once same time asstatic pressure reduced.

Tabular Printed Data One data reading per run for 15 rmsmeasurements

Magnetic Tape Raw signal

Infrared Data (using 8 deg lens)

Digital Data 1 frame every 4 sec

Tabular Printed Data (final) Assorted frames

Magnetic Tape All recorded data

Photographic Data (Calib. and Mat'l Eval. Phases)

Shadowgraph Stills Nominally, 1 sec after centerline

* Sequence Still Camera 1 every 4 sec(photos of IR monitor)

* Motion Picture Camera 8 frames per sed(movies of IR monitor)

(*) Motion Picture Camera (2) 24 and 400 frames per sec(movies of sample) r°55

Z .*--:. -" ". ".-'---' -,%- • • - ".-',' .. ...... .... i ' ,

U APPENDIX III4,

"' . SAMPLE TABULATED DATA

.

-..

4'f

.i

9 :,

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