Additively Manufactured Hypersonic Models with Embedded Instrumentation

ABSTRACT:Luna and MLPC are proposing to develop an innovative fabrication technique that embeds optical sensing fiber into an additively manufactured hypersonic test bed. Hypersonic testing of vehicles currently being performed in wind tunnels provides researchers with limited test data.Characterizing the complex phenomena under various replicated flight conditions can be an expensive and difficult process due to the number of models needed and the geometries of those models. An advanced modular test bed with leading edge and narrow taper capabilities is needed to enable the cost effective testing of components, validating hypersonic fluid dynamic models, and collect vital research data. Embedding Lunas unique fiber optic strain and temperature sensing solutions into these cones and leading edges using additive manufacturing will fill this void in test capabilities. During Phase I the team will design and test an article containing integrated sensors, which will demonstrate the feasibility of pairing the technologies. During Phase II the team will refine the design and develop processes, fabricate and evaluate additional test articles, and collect data currently unavailable using standard methods. During Phase III Luna will scale the processes and transition the technology to the Air Force.BENEFIT:The proposed system will meet the Air Forces need for a modular hypersonic test bed that facilitates integration of new sensing solutions. Temperature and strain sensors located non-intrusively near the leading edge of a cone or lifting body will enable measurements of localized parameter variations during hypersonic flow. These data can be used to increase the understanding of hypersonic flow problems and validate computational fluid dynamics (CFD) models. This technology is of value to the hypersonic test community, including the Air Force, Navy, NASA, Boeing, and Lockheed Martin. Additional commercial potential for this technology exists throughout a variety of industries. The ability to embed sensors into additively manufactured components opens the door to mass producible and cost effective smart components. Smart components will enable the automotive and aerospace industries to increase the safety, efficiency, and reliability of theirrespective products.