Heat flux sensor research and development: The cool film calorimeter

The goal was to meet the measurement requirement of the NASP program for a gauge capable of measuring heat flux into a 'typical' structure in a 'typical' hypersonic flight environment. A device is conceptually described that has fast response times and is small enough to fit in leading edge or cowl lip structures. The device relies heavily on thin film technology. The main conclusion is the description of the limitations of thin film technology both in the art of fabrication and in the assumption that thin films have the same material properties as the original bulk material. Three gauges were designed and fabricated. Thin film deposition processes were evaluated. The effect of different thin film materials on the performance and fabrication of the gauge was studied. The gauges were tested in an arcjet facility. Survivability and accuracy were determined under various hostile environment conditions.