Harsh-Environment Sensors for In-Flight Hypersonic Engine Tests

The Phase II proposal seeks to improve sensor concepts demonstrated under Phase I to meet program requirements for scramjet monitoring. Thermocouples, heat flux sensors and skin friction sensors were produced under Phase I using Mesoplasma direct write, a high precision derivative of thermal spray deposition processes. Under this phase of the program, a series of tests and design revisions are proposed which aim to improve sensor performance iteratively, by changing patterns, materials, deposition parameters, and by adding subtractive processing steps i.e., laser-cutting, to reduce sensor size and weight. Sensor specifications will be determined through consultation with program sponsors and program partner Pratt & Whitney Rocketdyne. Once sensor performance has been raised to a satisfactory level, these sensors will be fabricated onto real or simulated engine components, in locations of specific value for monitoring these systems. These instrumented components will be tested in representative environments to validate their usage in scramjet flight tests.