In Situ Diagnostic Sensors for Thermal Protection Systems

Low-profile, embedded sensors are proposed for condition monitoring and health management (HM) of thermal protection systems. The sensors will be fabricated using a high precision Direct Write (DW) process based upon thermal spray, affording them the advantages of high temperature tolerance, reproducibility, durability, and materials compatibility. In-situ sensing of temperature, heat flux, and surface recession will be demonstrated per the performance requirements specified for thermal protection systems. Relevant testing configurations will employ high temperature furnaces and flame rigs, specifically to validate sensor functionality, accuracy, and survivability. Sensor compatibility with TPS representative materials will also be considered to ensure seamless integration for rapid technology deployment. Having demonstrated their diagnostic capabilities, combining the sensors with DAQ and HM infrastructures would form the cornerstone of a potential Phase II, continuing application-specific development while expanding to address HM integration issues.