A Durable Heat Flux Sensor for Extreme Temperature and Heat Flux Environments

This project is the development and evaluation of a novel heat flux sensor, the High Temperature Heat Flux Sensor (HTHFS), capable of long term operation at temperatures and heat flux levels in excess of 1000°C and 10 W/cm² respectively. The current sensor configuration utilizes type-K thermocouple materials in a durable welded thermopile arrangement. The steady-state thermoelectric sensitivity of the design is predicted using a one-dimensional thermal resistance model and the Seebeck coefficient of the thermocouple materials. The design performances of three sensors are validated using a convection heat transfer calibration facility. Average experimental values of the sensitivity are 1020, 1031, and 1208 ìV/W/cm² respectively for heat transfer coefficients ranging from 0.03 to 0.11 W/cm²-°C, with one sensor calibrated after thermal cycling. Prolonged thermal cycling of a representative gage in air demonstrates survivability near the maximum temperature of the thermoelectric materials with minimal oxidation or loss of calibration. Repeated propane torch tests also demonstrate functionality in a realistic environment.

To see the resume of the expert associated with this case study, see the link below.