CONJUGATE HEAT TRANSFER AND THERMO-STRUCTURAL ANALYSIS OF THE ACTIVELY COOLED MULTI-STAGE CONICAL NOZZLE AND HYPERSONIC LOW-REYNOLDS DIFFUSER OF THE NEW ARC-HEATED WIND TUNNEL (AWHT-II) OF THE UNIVERSITY OF TEXAS AT ARLINGTON

Abstract

Arc-heated wind tunnels are the primary test facility for screening and qualification of candidate materials for hypersonic thermal protection systems (TPS). Via an electric arc that largely augments the enthalpy (by tens of MJ/kg) of the working fluid (Air, Nitrogen, CO2 in case of Mars-entry studies) passed through a converging-diverging nozzle at specific stagnation conditions, different regimes encountered in entry and re-entry hypersonic aerothermodynamics can be simulated. Because of the high-enthalpies (and associated temperatures that generally exceed the limits required by the thermo-structural integrity of the facility) the active cooling of the arc-heated wind tunnel’s parts exposed to the working gas is critical. This criticality is particularly severe in these facilities due to the time scales associated with their continuous operation capabilities (order of minutes). This research focuses on the design and the conjugate heat transfer and resultant thermo-structural analysis of a multi-segment nozzle and low-Reynolds, hypersonic diffuser for the new arc-heated wind tunnel (AHWT-II) of the University of Texas at Arlington. Nozzles and hypersonic diffusers are critical components that experience highly complex flows (non-equilibrium aerothermochemistry) and high (local and distributed) heat-flux loads which significantly augment the complexity of the problems associated with their thermal management. The proper design and thermo-mechanical analysis of these components are crucial elements for the operability of the new facility. This work is centered on the design considerations, methodologies and the detailed analysis of the aforementioned components which resulted in the definition of final parts and assemblies that are under manufacturing at this writing. The project is jointly sponsored by the Office of Naval Research (ONR) and the Defense Advanced Research Project Agency (DARPA).