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Methods and procedures for evaluating, forming, and installing small diameter thermocouple wire and sheathed thermocouples
Two simple, effective techniques for attaching thermocouples to metal substrates have been devised for high-temperature applications in which attachment by such conventional means as welding, screws, epoxy, or tape would not be effective. The techniques have been used successfully to attach 0.005- in. (0.127-mm)-diameter type-S thermocouples to substrates of niobium alloy C-103 and stainless steel 416 for measuring temperatures up to 2,600 F (1,427 C). The techniques are equally applicable to other thermocouple and substrate materials. In the first technique, illustrated in the upper part of the figure, a hole slightly wider than twice the diameter of one thermocouple wire is drilled in the substrate. The thermocouple is placed in the hole, then the edge of the hole is peened in one or more places by use of a punch (see figure). The deformed material at the edge secures the thermocouple in the hole. In the second technique a hole is drilled as in the first technique, then an annular relief area is machined around the hole, resulting in structure reminiscent of a volcano in a crater. The thermocouple is placed in the hole as in the first technique, then the "volcano" material is either peened by use of a punch or crimped by use of sidecutters to secure the thermocouple in place. This second technique is preferable for very thin thermocouples [wire diameter .0.005 in. (.0.127 mm)] because standard peening poses a greater risk of clipping one or both of the thermocouple wires. These techniques offer the following advantages over prior thermocouple-attachment techniques: . Because these techniques involve drilling of very small holes, they are minimally invasive . an important advantage in that, to a first approximation, the thermal properties of surrounding areas are not appreciably affected. . These techniques do not involve introduction of any material, other than the substrate and thermocouple materials, that could cause contamination, could decompose, or oxidize at high measurement temperatures. . The simplicity of these techniques makes it possible to attach thermocouples quickly. . These techniques can be used to attach thermocouples at locations where access is somewhat restricted by the surrounding objects.
A straightforward measurement technique provides for correction of thermal-electromotive-force (thermal-EMF) errors introduced by temperature gradients along the pins of non-thermocouple-alloy hermetic feedthrough connectors for thermocouple extension wires that must pass through bulkheads. This technique is an alternative to the traditional technique in which the thermal-EMF errors are eliminated by use of custom-made multipin hermetic feedthrough connectors that contain pins made of the same alloys as those of the thermocouple extension wires. One disadvantage of the traditional technique is that it is expensive and time-consuming to fabricate multipin custom thermocouple connectors. In addition, the thermocouple-alloy pins in these connectors tend to corrode easily and/or tend to be less rugged compared to the non-thermocouple-alloy pins of ordinary connectors. As the number of thermocouples (and thus pins) is increased in a given setup, the magnitude of these disadvantages increases accordingly. The present technique is implemented by means of a little additional hardware and software, the cost of which is more than offset by the savings incurred through the use of ordinary instead of thermocouple connectors. The figure schematically depicts a typical measurement setup to which the technique is applied. The additional hardware includes an isothermal block (made of copper) instrumented with a reference thermocouple and a compensation thermocouple. The reference thermocouple is connected to an external data-acquisition system (DAS) through a two-pin thermocouple-alloy hermetic feedthrough connector, but this is the only such connector in the apparatus. The compensation thermocouple is connected to the DAS through two pins of the same ordinary multipin connector that connects the measurement thermocouples to the DAS.
The Sensors and Electronics Technology Branch of the NASA Glenn Research Center is developing thin-film-based sensors for surface measurement in propulsion system research. Thin-film sensors do not require special machining of the components on which they are mounted, and they are considerably thinner than wire- or foil-based sensors. One type of sensor being advanced is the thin-film thermocouple, specifically for applications in high-temperature combustion environments. Ceramics are being demonstrated as having the potential to meet the demands of thin-film thermocouples in advanced aerospace environments. The maximum-use temperature of noble metal thin-film thermocouples, 1500 C (2700 F), may not be adequate for components used in the increasingly harsh conditions of advanced aircraft and next-generation launch vehicles. Ceramic-based thermocouples are known for their high stability and robustness at temperatures exceeding 1500 C, but are typically in the form of bulky rods or probes. As part of ASTP, Glenn's Sensors and Electronics Technology Branch is leading an in-house effort to apply ceramics as thin-film thermocouples for extremely high-temperature applications as part of ASTP. Since the purity of the ceramics is crucial for the stability of the thermocouples, Glenn's Ceramics Branch and Case Western Reserve University are developing high-purity ceramic sputtering targets for fabricating high-temperature sensors. Glenn's Microsystems Fabrication Laboratory, supported by the Akima Corporation, is using these targets to fabricate thermocouple samples for testing. The first of the materials used were chromium silicide (CrSi) and tantalum carbide (TaC). These refractory materials are expected to survive temperatures in excess of 1500 C. Preliminary results indicate that the thermoelectric voltage output of a thin-film CrSi versus TaC thermocouple is 15 times that of the standard type R (platinum-rhodium versus platinum) thermocouple, producing 20 mV with a 200 C temperature gradient. The photograph on the left shows the CrSi-TaC thermocouple in a test fixture at Glenn, and the resulting output signal is shown on the right. The temperature differential across the sample, from the center of the sample inside the oven to the sample mount outside the oven, is measured using a type R thermocouple on the sample.
It is often impractical to instrument the external surface of high-speed vehicles due to the aerothermodynamic heating. Temperatures can instead be measured internal to the structure using embedded thermocouples, and direct and inverse methods can then be used to estimate temperature and heat flux on the external surface. Two thermocouples embedded at different depths are required to solve direct and inverse problems, and filtering schemes are used to reduce noise in the measured data. Accuracy in the estimated surface temperature and heat flux is dependent on several factors. Factors include the thermocouple location through the thickness of a material, the sensitivity of the surface solution to the error in the specified location of the embedded thermocouples, and the sensitivity to the error in thermocouple data. The effect of these factors on solution accuracy is studied using the methodology discussed in the work of Pizzo, et. al.1 A numerical study is performed to determine if there is an optimal depth at which to embed one thermocouple through the thickness of a material assuming that a second thermocouple is installed on the back face. Solution accuracy will be discussed for a range of embedded thermocouple depths. Moreover, the sensitivity of the surface solution to (a) the error in the specified location of the embedded thermocouple and to (b) the error in the thermocouple data are quantified using numerical simulation, and the results are discussed.
Experimental measurements are made with a novel two wire thermocouple. Signals from two wires of unequal diameters are recorded from the thermocouple suspended in constant flow with a periodic temperature fluctuation. It is demonstrated that the reconstructed signal from the two wire thermocouple requires no compensation for omega less than or equal to 2 omega(sub 1) where omega is the natural frequency of the smaller wire. A compensation factor is recommended for larger frequencies omega greater than 2 omega(sub 1). Theory and experimental measurements are compared with a novel three wire thermocouple. Signals from three wires of unequal diameters are recorded from the thermocouple suspended in constant flow with a periodic temperature fluctuation. It is demonstrated that the reconstructed signal from the three wire thermocouple requires no compensation for omega less than or equal to 5 omega(sub 1) where omega (sub 1) is the natural frequency of the smaller wire. The latter result represents a significant improvement compared to previous work with two wire thermocouples. A correction factor has also been derived to account for wires of arbitrary diameter. Measurements are recorded for multiwire thermocouples consisting of either two or three wires of unequal diameters. Signals from the multiwire probe are recorded for a reversing gas flow with a periodic temperature fluctuation. It is demonstrated that the reconstructed signal from the multiwire thermocouple requires no compensation provided omega/omega(sub 1) is less than 2.3 for two wires or omega/omega(sub 1) is less than 3.6 for three wires where omega(sub 1) is the natural frequency of the smaller wire based on the maximum gas velocity. The latter results were possible provided Fourier transformed data were used and knowledge of the gas velocity is available.
Thin film thermocouples have been developed for use on metal parts in jet engines to 1000 C. However, advanced propulsion systems are being developed that will use ceramic materials and reach higher temperatures. The purpose of this work is to develop thin film thermocouples for use on ceramic materials. The thin film thermocouples are Pt13Rh/Pt fabricated by the sputtering process. Lead wires are attached using the parallel-gap welding process. The ceramic materials are silicon nitride, silicon carbide, aluminum oxide, and mullite. Both steady state and thermal cycling furnace tests were performed in the temperature range to 1500 C. High-heating-rate tests were performed in an arc lamp heat-flux-calibration facility. The fabrication of the thin film thermocouples is described. The thin film thermocouple output was compared to a reference wire thermocouple. Drift of the thin film thermocouples was determined, and causes of drift are discussed. The results of high-heating-rate tests up to 2500 C/sec are presented. The stability of the ceramic materials is examined. It is concluded that Pt13Rh/Pt thin film thermocouples are capable of meeting lifetime goals of 50 hours or more up to temperatures of 1500 C depending on the stability of the particular ceramic substrate.
Thin film thermocouples were developed for use on metal parts in jet engines to 1000 C. However, advanced propulsion systems are being developed that will use ceramic materials and reach higher temperatures. The purpose is to develop thin film thermocouples for use on ceramic materials. The new thin film thermocouples are Pt13Rh/Pt fabricated by the sputtering process. Lead wires are attached using the parallel-gap welding process. The ceramic materials tested are silicon nitride, silicon carbide, aluminum oxide, and mullite. Both steady state and thermal cycling furnace tests were performed in the temperature range to 1500 C. High-heating-rate tests were performed in an arc lamp heat-flux-calibration facility. The fabrication of the thin film thermocouples is described. The thin film thermocouple output was compared to a reference wire thermocouple. Drift of the thin film thermocouples was determined, and causes of drift are discussed. The results of high heating rate tests up to 2500 C/sec are presented. The stability of the ceramic materials is examined. It is concluded that Pt13Rh/Pt thin film thermocouples are capable of meeting lifetime goals of 50 hr or more up to temperatures of 1500 C depending on the stability of the particular ceramic substrate.
An improved self-validating thermocouple (SVT) instrumentation system not only acquires readings from a thermocouple but is also capable of detecting deterioration and a variety of discrete faults in the thermocouple and its lead wires. Prime examples of detectable discrete faults and deterioration include open- and short-circuit conditions and debonding of the thermocouple junction from the object, the temperature of which one seeks to measure. Debonding is the most common cause of errors in thermocouple measurements, but most prior SVT instrumentation systems have not been capable of detecting debonding. The improved SVT instrumentation system includes power circuitry, a cold-junction compensator, signal-conditioning circuitry, pulse-width-modulation (PWM) thermocouple-excitation circuitry, an analog-to-digital converter (ADC), a digital data processor, and a universal serial bus (USB) interface. The system can operate in any of the following three modes: temperature measurement, thermocouple validation, and bonding/debonding detection. The software running in the processor includes components that implement statistical algorithms to evaluate the state of the thermocouple and the instrumentation system. When the power is first turned on, the user can elect to start a diagnosis/ monitoring sequence, in which the PWM is used to estimate the characteristic times corresponding to the correct configuration. The user also has the option of using previous diagnostic values, which are stored in an electrically erasable, programmable read-only memory so that they are available every time the power is turned on.
Thin film thermocouples have been developed for use on metal parts in jet engines to 1000 c. However, advanced propulsion systems are being developed that will use ceramic materials and reach higher temperatures. The purpose of this work is to develop thin film thermocouples for use on ceramic materials. The new thin film thermocouples are Pt13Rh/Pt fabricated by the sputtering process. Lead wires are attached using the parallel-gap welding process. The ceramic materials tested are silicon nitride, silicon carbide, aluminum oxide, and mullite. Both steady state and thermal cycling furnace tests were performed in the temperature range to 1500 C. High-heating-rate tests were performed in an arc lamp heat-flux-calibration facility. The fabrication of the thin film thermocouples is described. The thin film thermocouple output was compared to a reference wire thermocouple. Drift of the thin film thermocouples was determined, and causes of drift are discussed. The results of high heating rate tests up to 2500 C/sec are presented. The stability of the ceramic materials is examined. It is concluded that Pt13Rh/Pt thin film thermocouples are capable of meeting lifetime goals of 50 hours or more up to temperature of 1500 C depending on the stability of the particular ceramic substrate.
Laboratory testing of advanced aerospace components very often requires highly accurate temperature measurement and control devices, as well as methods to precisely analyze and predict the performance of such components. Analysis of test articles depends on accurate measurements of temperature across the specimen. Where possible, this task is accomplished using many thermocouples welded directly to the test specimen, which can produce results with great precision. However, it is known that thermocouple spot welds can initiate deleterious cracks in some materials, prohibiting the use of welded thermocouples. Such is the case for the nickel-based superalloy MarM-247, which is used in the high temperature, high pressure heater heads for the Advanced Stirling Converter component of the Advanced Stirling Radioisotope Generator space power system. To overcome this limitation, a method was developed that uses small diameter contact thermocouples to measure the temperature of heater head test articles with the same level of accuracy as welded thermocouples. This paper includes a brief introduction and a background describing the circumstances that compelled the development of the contact thermocouple measurement method. Next, the paper describes studies performed on contact thermocouple readings to determine the accuracy of results. It continues on to describe in detail the developed measurement method and the evaluation of results produced. A further study that evaluates the performance of different measurement output devices is also described. Finally, a brief conclusion and summary of results is provided.
An investigation was made of sheathed thermocouples for turbine blade temperature measurements. Tests were performed on the Chromel-Alumel sheathed thermocouples with both two-wire and single-wire configurations. Sheath diameters ranged from 0.25 to 0.76 mm, and temperatures ranged from 1080 to 1250 K. Both steady-state and thermal cycling tests were performed for times up to 450 hr. Special-order and commercial-grade thermocouples were tested. The tests showed that special-order single-wire sheathed thermocouples can be obtained that are reliable and accurate with diameters as small as 0.25 mm. However, all samples of 0.25-mm-diameter sheathed commercial-grade two-wire and single-wire thermocouples that were tested showed unacceptable drift rates for long-duration engine testing programs. The drift rates were about 1 percent in 10 hr. A thermocouple drift test is recommended in addition to the normal acceptance tests in order to select reliable miniature sheathed thermocouples for turbine blade applications.
A new thermocouple pairing was formed by combining thermocouple elements from two existing commercially available thermocouples to form a new combination (Ir-40 Rh/Pt-40 Rh) thermocouple. The output of this new pairing is nearly linear with temperature, and approximately equal to the output of one of the originating pairs (Ir-40 Rh/Ir), and more than double that of the other pair (Pt-40 Rh/Pt-20 Rh). This new pairing was evolved during a search for a noble-metal thermocouple combination which could operate above the temperature limit of a Pt-13 Rh/Pt thermocouple and have a higher oxidation resistance than an Ir-40 Rh/Ir thermocouple.
Thermocouples of the present invention provide stability and performance reliability in systems involving high temperatures and vacuums by employing a bimetallic thermocouple sensor wherein each metal of the sensor is selected from a group of metals comprising tantalum and rhenium and alloys containing only those two metals. The tantalum, rhenium thermocouple sensor alloys provide bare metal thermocouple sensors having advantageous vapor pressure compatibilities and performance characteristics. The compatibility and physical characteristics of the thermocouple sensor alloys of the present invention result in improved emf, temperature properties and thermocouple hot junction performance. The thermocouples formed of the tantalum, rhenium alloys exhibit reliability and performance stability in systems involving high temperatures and vacuums and are adaptable to space propulsion and power systems and nuclear environments.
Thin film thermocouples provide a minimally intrusive means of measuring surface temperature in hostile, high temperature environments. Unlike wire thermocouples, thin films do not necessitate any machining of the surface, therefore leaving intact its structural integrity. Thin films are many orders of magnitude thinner than wire, resulting in less disruption to the gas flow and thermal patterns that exist in the operating environment. Thin film thermocouples have been developed for surface temperature measurement on a variety of engine materials. The sensors are fabricated in the NASA Lewis Research Center's Thin Film Sensor Lab, which is a class 1000 clean room. The thermocouples are platinum-13 percent rhodium versus platinum and are fabricated by the sputtering process. Thin film-to-leadwire connections are made using the parallel-gap welding process. Thermocouples have been developed for use on superalloys, ceramics and ceramic composites, and intermetallics. Some applications of thin film thermocouples are: temperature measurement of space shuttle main engine turbine blade materials, temperature measurement in gas turbine engine testing of advanced materials, and temperature and heat flux measurements in a diesel engine. Fabrication of thin film thermocouples is described. Sensor durability, drift rate, and maximum temperature capabilities are addressed.
Post-test examination and data analysis that followed a two week long vacuum test showed that numerous self-stick thermocouples became detached from the test article. The thermocouples were reattached with thermally conductive epoxy and the test was repeated to obtain the required data. Because the thermocouple detachment resulted in significant expense and rework, it was decided to investigate the temporary attachment methods used around NASA and to perform a test to assess their efficacy. The present work describes the testing that was performed in early and mid-2017. The test article and the temporary thermocouple attachment methods tested are described. During the first test, fully half of the thermocouples detached - although the detachment showed subtly in the data for some. The second test was performed to confirm the data from the first test and to investigate the effect of test article and thermocouple grounding. The results of the testing over temperatures ranging from -150 to 200degF are detailed and preliminary recommendations are made for temporary thermocouple attachment methods.
Seven tantalum sheathed, BeO insulated, 0.157-cm-diam, grounded-junction W-3%Re/W-25%Re thermocouples were irradiated in a helium-argon environment at a temperature of 1900 to 2100 K. Six other thermocouples from the same lot were operated out-of-pile with the same temperature history as the in-pile thermocouples. Drift-in-pile was determined by periodically replacing a 'reference' thermocouple in the irradiation capsule. Drift out-of-pile was determined with an optical pyrometer. After 8000 hours irradiation, the estimated neutron fluence was 4 x 10 to the 21st power thermal neutrons/sq cm and 0.9 x 10 to the 21st power fast neutrons/sq cm (E greater than 0.18 MeV). At this time the in-pile group had decreased in output the equivalent of 340 K at 2073 K, while the out-of-pile group had decreased in output the equivalent of 54 K at 2073 K. The maximum deviation in drift between thermocouples of the in-pile group and between thermocouples of the out-of-pile group was less than plus or minus 15 K and less than plus or minus 10 K, respectively.
Tantalum sheathed, BeO insulated, W-3% Re/W-25% Re thermocouple assemblies were fabricated and their emf drift determined during 2059 hours of exposure at 2073 K in a gaseous helium environment. The sheathed thermocouple assemblies were constructed from aged thermoelements, specially heat-treated BeO insulators, and specially cleaned and etched tantalum sheaths. Their thermal emf drifts ranged from the equivalent of only -0.3 to -0.8 K drift per 1000 hours of exposure at 2073 K. No evidence of any gross chemical attack or degradation of the component materials was found. The emf drift and material behavior of some unsheathed, BeO insulated, W-3% Re/W-25% Re thermocouples at 2250 and 2400 K were also determined. Unsheathed thermocouples tested in an argon environment at 2250 K for 1100 hours and at 2400 K for 307 hours exhibited changes in thermal emf that typically ranged from the equivalent of a few degrees K to as much as +11 K. Post-test examinations of these thermocouples revealed some undesirable material degradation and interaction which included erosion of the BeO insulators and contamination of the thermoelements by tantalum from the tantalum blackbody enclosure in which the thermocouples were contained.