Fabricating Thin-Shell Heat-Transfer Models

Freestanding shells produced for experimental aerodynamic-heating tests. Heat transfer shells require several steps and several precise molds. First, interlocking aluminum male and female molds fabricated. Holes for thermocouples drilled through male mold at desired locations. Wires having same diameter as thermocouple wire placed through holes in male mold flush to female mold. Epoxy exposed to vacuum to remove air bubbles poured between male and female molds to form thin female mold. Once mold cured, wires removed and aluminum molds separated.