Rapid Fabrication of Flat Plate Cavity Phosphor Thermography Test Models for Shuttle Return-to-Flight Aero-Heating

Methods, materials and equipment are documented for fabricating flat plate test models at NASA Langley Research Center for Shuttle return-to-flight aeroheating experiments simulating open and closed cavity interactions in Langley s hypersonic 20-Inch Mach 6 air wind tunnel. Approximately 96 silica ceramic flat plate cavity phosphor thermography test models have been fabricated using these methods. On one model, an additional slot is machined through the back of the plate and into the cavity and vented into an evacuated plenum chamber to simulate a further opening in the cavity. After sintering ceramic to 2150 F, and mounting support hardware, a ceramic-based two-color thermographic phosphor coating is applied for global temperature and heat transfer measurements, with fiducial markings for image registration.