Richard J. Schwartz

The HYTHIRM Project: Flight Thermography of the Space Shuttle During the Hypersonic Re-entry

This report describes a NASA Langley led endeavor sponsored by the NASA Engineering Safety Center, the Space Shuttle Program Office and the NASA Aeronautics Research Mission Directorate to demonstrate a quantitative thermal imaging capability. A background and an overview of several multidisciplinary efforts that culminated in the acquisition of high resolution calibrated infrared imagery of the Space Shuttle during hypervelocity atmospheric entry is presented. The successful collection of thermal data has demonstrated the feasibility of obtaining remote high-resolution infrared imagery during hypersonic flight for the accurate measurement of surface temperature. To maximize science and engineering return, the acquisition of quantitative thermal imagery and capability demonstration was targeted towards three recent Shuttle flights - two of which involved flight experiments flown on Discovery. In coordination with these two Shuttle flight experiments, a US Navy NP-3D aircraft was flown between 26-41 nautical miles below Discovery and remotely monitored surface temperature of the Orbiter at Mach 8.4 (STS-119) and Mach 14.7 (STS-128) using a long-range infrared optical package referred to as Cast Glance. This same Navy aircraft successfully monitored the Orbiter Atlantis traveling at approximately Mach 14.3 during its return from the successful Hubble repair mission (STS-125). The purpose of this paper is to describe the systematic approach used by the Hypersonic Thermodynamic Infrared Measurements team to develop and implement a set of mission planning tools designed to establish confidence in the ability of an imaging platform to reliably acquire, track and return global quantitative surface temperatures of the Shuttle during entry. The mission planning tools included a pre-flight capability to predict the infrared signature of the Shuttle. Such tools permitted optimization of the hardware configuration to increase signal-to-noise and to maximize the available dynamic range while mitigating the potential for saturation. Post flight, analysis tools were used to assess atmospheric effects and to convert the 2-D intensity images to 3-D temperature maps of the windward surface. Comparison of the spatially resolved global thermal measurements to surface thermocouples and CFD prediction is made. Successful demonstration of a quantitative, spatially resolved, global temperature measurement on the Shuttle suggests future applications towards hypersonic flight test programs within NASA, DoD and DARPA along with flight test opportunities supporting NASAs project Constellation.

Shuttle Entry Imaging Using Infrared Thermography

During the Columbia Accident Investigation, imaging teams supporting debris shedding analysis were hampered by poor entry image quality and the general lack of information on optical signatures associated with a nominal Shuttle entry. After the accident, recommendations were made to NASA management to develop and maintain a state-of-the-art imagery database for Shuttle engineering per-formance assessments and to improve entry imaging capability to support anomaly and contingency analysis during a mission. As a result, the Space Shuttle Program sponsored an observation campaign to qualitatively characterize a nominal Shuttle entry over the widest possible Mach number range. The initial objectives focused on an assessment of capability to identify/resolve debris liberated from the Shuttle during entry, characterization of potential anomalous events associated with RCS jet fir-ings and unusual phenomenon associated with the plasma trail. The aeroheating technical community viewed the Space Shuttle Program sponsored activity as an opportunity to influence the observation objectives and incrementally demonstrate key elements of a quantitative spatially resolved tempera-ture measurement capability over a series of flights. One long-term desire of the Shuttle engineering community is to calibrate boundary layer transition prediction methodologies that are presently part of the Shuttle damage assessment process using flight data provided by a controlled Shuttle flight ex-periment. Quantitative global imaging may offer a complementary method of data collection to more traditional methods such as surface thermocouples. This paper reviews the process used by the engi-neering community to influence data collection methods and analysis of global infrared images of the Shuttle obtained during hypersonic entry. Emphasis is placed upon airborne imaging assets sponsored by the Shuttle program during Return to Flight. Visual and IR entry imagery were obtained with available airborne imaging platforms used within DoD along with agency assets developed and opti-mized for use during Shuttle ascent to demonstrate capability (i.e., tracking, acquisition of multispectral data, spatial resolution) and identify system limitations (i.e., radiance modeling, satura-tion) using state-of-the-art imaging instrumentation and communication systems. Global infrared intensity data have been transformed to temperature by comparison to Shuttle flight thermocouple data. Reasonable agreement is found between the flight thermography images and numerical predic-tion. A discussion of lessons learned and potential application to a potential Shuttle boundary layer transition flight test is presented.

Assessment and Mission Planning Capability For Quantitative Aerothermodynamic Flight Measurements Using Remote Imaging

High resolution calibrated infrared imagery of vehicles during hypervelocity atmospheric entry or sustained hypersonic cruise has the potential to provide flight data on the distribution of surface temperature and the state of the airflow over the vehicle. In the early 1980 s NASA sought to obtain high spatial resolution infrared imagery of the Shuttle during entry. Despite mission execution with a technically rigorous pre-planning capability, the single airborne optical system for this attempt was considered developmental and the scientific return was marginal. In 2005 the Space Shuttle Program again sponsored an effort to obtain imagery of the Orbiter. Imaging requirements were targeted towards Shuttle ascent; companion requirements for entry did not exist. The engineering community was allowed to define observation goals and incrementally demonstrate key elements of a quantitative spatially resolved measurement capability over a series of flights. These imaging opportunities were extremely beneficial and clearly demonstrated capability to capture infrared imagery with mature and operational assets of the US Navy and the Missile Defense Agency. While successful, the usefulness of the imagery was, from an engineering perspective, limited. These limitations were mainly associated with uncertainties regarding operational aspects of data acquisition. These uncertainties, in turn, came about because of limited pre-flight mission planning capability, a poor understanding of several factors including the infrared signature of the Shuttle, optical hardware limitations, atmospheric effects and detector response characteristics. Operational details of sensor configuration such as detector integration time and tracking system algorithms were carried out ad hoc (best practices) which led to low probability of target acquisition and detector saturation. Leveraging from the qualified success during Return-to-Flight, the NASA Engineering and Safety Center sponsored an assessment study focused on increasing the probability of returning spatially resolved scientific/engineering thermal imagery. This paper provides an overview of the assessment task and the systematic approach designed to establish confidence in the ability of existing assets to reliably acquire, track and return global quantitative surface temperatures of the Shuttle during entry. A discussion of capability demonstration in support of a potential Shuttle boundary layer transition flight test is presented. Successful demonstration of a quantitative, spatially resolved, global temperature measurement on the proposed Shuttle boundary layer transition flight test could lead to potential future applications with hypersonic flight test programs within the USAF and DARPA along with flight test opportunities supporting NASA s project Constellation.

Processing near-infrared imagery of hypersonic space shuttle reentries

High-resolution, calibrated, near-infrared imagery of the Space Shuttle during reentry has been obtained by a US Navy NP-3D Orion aircraft as part of NASAs HYTHIRM (Hypersonic Thermodynamic InfraRed Measurements) project. The long-range optical sensor package is called Cast Glance. Three sets of imagery have been processed thus far: 1) STS- 119 when Shuttle Discovery was at 52 km away at Mach 8.4, 2) STS-125 when Shuttle Atlantis was 71 km away at Mach 14.3, and 3) STS-128 when Shuttle Discovery was at 80 km away at Mach 14.7. The challenges presented in processing a manually-tracked high-angular rate, air-to-air image data collection include management of significant frame-to-frame motions, motion-induced blurring, changing orientations and ranges, daylight conditions, and sky backgrounds (including some cirrus clouds). This paper describes processing the imagery to estimate Shuttle surface temperatures. Our goal is to reduce the detrimental effects due to motions (sensor and Shuttle), vibration, and atmospherics for image quality improvement, without compromising the quantitative integrity of the data, especially local intensity variations. Our approach is to select and utilize only the highest quality images, register many cotemporal image frames to a single image frame, and then add the registered frames to improve image quality and reduce noise. These registered and averaged intensity images are converted to temperatures on the Shuttles windward surface using a series of steps starting with preflight calibration data. Comparisons with thermocouples at different points along the space Shuttle and between the three reentries will be shown.

A Vision of Quantitative Imaging Technology for Validation of Advanced Flight Technologies

Flight-testing is traditionally an expensive but critical element in the development and ultimate validation and certification of technologies destined for future operational capabilities. Measurements obtained in relevant flight environments also provide unique opportunities to observe flow phenomenon that are often beyond the capabilities of ground testing facilities and computational tools to simulate or duplicate. However, the challenges of minimizing vehicle weight and internal complexity as well as instrumentation bandwidth limitations often restrict the ability to make high-density, in-situ measurements with discrete sensors. Remote imaging offers a potential opportunity to noninvasively obtain such flight data in a complementary fashion. The NASA Hypersonic Thermodynamic Infrared Measurements Project has demonstrated such a capability to obtain calibrated thermal imagery on a hypersonic vehicle in flight. Through the application of existing and accessible technologies, the acreage surface temperature of the Shuttle lower surface was measured during reentry. Future hypersonic cruise vehicles, launcher configurations and reentry vehicles will, however, challenge current remote imaging capability. As NASA embarks on the design and deployment of a new Space Launch System architecture for access beyond earth orbit (and the commercial sector focused on low earth orbit), an opportunity exists to implement an imagery system and its supporting infrastructure that provides sufficient flexibility to incorporate changing technology to address the future needs of the flight test community. A long term vision is offered that supports the application of advanced multi-waveband sensing technology to aid in the development of future aerospace systems and critical technologies to enable highly responsive vehicle operations across the aerospace continuum, spanning launch, reusable space access and global reach. Motivations for development of an Agency level imagery-based measurement capability to support cross cutting applications that span the Agency mission directorates as well as meeting potential needs of the commercial sector and national interests of the Intelligence, Surveillance and Reconnaissance community are explored. A recommendation is made for an assessment study to baseline current imaging technology including the identification of future mission requirements. Development of requirements fostered by the applications suggested in this paper would be used to identify technology gaps and direct roadmapping for implementation of an affordable and sustainable next generation sensor/platform system.

Solar Tower Experiments for Radiometric Calibration and Validation of Infrared Imaging Assets and Analysis Tools for Entry Aero-Heating Measurements

The NASA Engineering and Safety Center sponsored Hypersonic Thermodynamic Infrared Measurements assessment team has a task to perform radiometric calibration and validation of land-based and airborne infrared imaging assets and tools for remote thermographic imaging. The IR assets and tools will be used for thermographic imaging of the Space Shuttle Orbiter during entry aero-heating to provide flight boundary layer transition thermography data that could be utilized for calibration and validation of empirical and theoretical aero-heating tools. A series of tests at the Sandia National Laboratories National Solar Thermal Test Facility were designed for this task where reflected solar radiation from a field of heliostats was used to heat a 4 foot by 4 foot test panel consisting of LI 900 ceramic tiles located on top of the 200 foot tall Solar Tower. The test panel provided an Orbiter-like entry temperature for the purposes of radiometric calibration and validation. The Solar Tower provided an ideal test bed for this series of radiometric calibration and validation tests because it had the potential to rapidly heat the large test panel to spatially uniform and non-uniform elevated temperatures. Also, the unsheltered-open-air environment of the Solar Tower was conducive to obtaining unobstructed radiometric data by land-based and airborne IR imaging assets. Various thermocouples installed on the test panel and an infrared imager located in close proximity to the test panel were used to obtain surface temperature measurements for evaluation and calibration of the radiometric data from the infrared imaging assets. The overall test environment, test article, test approach, and typical test results are discussed.

Global Thermography of the Space Shuttle During Hypersonic Re-entry

Three dimensional surface thermography of the windward side of the Space Shuttle based on near infrared measurements is presented for STS-119, STS-125, STS-128, STS-132 and STS-133 reentries. A method used to project 2-D imagery to 3-D surface geometry is used to improve on previously used iterative method both in accuracy and in computational speed. Effects of material dependent surface spectral emissivities, image blurring and image-model alignment are all seen to have strong effects on the resultant temperature map. Results indicate best surface temperature accuracies in regions of small thermal gradients. Acronyms

Remote Infrared Imaging of the Space Shuttle During Hypersonic Flight: HYTHIRM Mission Operations and Coordination

The Hypersonic Thermodynamic Infrared Measurements (HYTHIRM) project has been responsible for obtaining spatially resolved, scientifically calibrated in-flight thermal imagery of the Space Shuttle Orbiter during reentry. Starting with STS-119 in March of 2009 and continuing through to the majority of final flights of the Space Shuttle, the HYTHIRM team has to date deployed during seven Shuttle missions with a mix of airborne and ground based imaging platforms. Each deployment of the HYTHIRM team has resulted in obtaining imagery suitable for processing and comparison with computational models and wind tunnel data at Mach numbers ranging from over 18 to under Mach 5. This paper will discuss the detailed mission planning and coordination with the NASA Johnson Space Center Mission Control Center that the HYTHIRM team undergoes to prepare for and execute each mission.

Infrared Imaging of Boundary Layer Transition Flight Experiments

The Hypersonic Thermodynamic Infrared Measurement (HYTHIRM) project is presently focused on near term support to the Shuttle program through the development of an infrared imaging capability of sufficient spatial and temporal resolution to augment existing on-board Orbiter instrumentation. Significant progress has been made with the identification and inventory of relevant existing optical imaging assets and the development, maturation, and validation of simulation and modeling tools for assessment and mission planning purposes, which were intended to lead to the best strategies and assets for successful acquisition of quantitative global surface temperature data on the Shuttle during entry. However, there are longer-term goals of providing global infrared imaging support to other flight projects as well. A status of HYTHIRM from the perspective of how two NASA-sponsored boundary layer transition flight experiments could benefit by infrared measurements is provided. Those two flight projects are the Hypersonic Boundary layer Transition (HyBoLT) flight experiment and the Shuttle Boundary Layer Transition Flight Experiment (BLT FE), which are both intended for reducing uncertainties associated with the extrapolation of wind tunnel derived transition correlations for flight application. Thus, the criticality of obtaining high quality flight data along with the impact it would provide to the Shuttle program damage assessment process are discussed. Two recent wind tunnel efforts that were intended as risk mitigation in terms of quantifying the transition process and resulting turbulent wedge locations are briefly reviewed. Progress is being made towards finalizing an imaging strategy in support of the Shuttle BLT FE, however there are no plans currently to image HyBoLT.

Thermographic imaging of the space shuttle during re-entry using a near-infrared sensor

High resolution calibrated near infrared (NIR) imagery of the Space Shuttle Orbiter was obtained during hypervelocity atmospheric re-entry of the STS-119, STS-125, STS-128, STS-131, STS-132, STS-133, and STS-134 missions. This data has provided information on the distribution of surface temperature and the state of the airflow over the windward surface of the Orbiter during descent. The thermal imagery complemented data collected with onboard surface thermocouple instrumentation. The spatially resolved global thermal measurements made during the Orbiters hypersonic re-entry will provide critical flight data for reducing the uncertainty associated with present day ground-to-flight extrapolation techniques and current state-of-the-art empirical boundary-layer transition or turbulent heating prediction methods. Laminar and turbulent flight data is critical for the validation of physics-based, semi-empirical boundary-layer transition prediction methods as well as stimulating the validation of laminar numerical chemistry models and the development of turbulence models supporting NASAs next-generation spacecraft. In this paper we provide details of the NIR imaging system used on both air and land-based imaging assets. The paper will discuss calibrations performed on the NIR imaging systems that permitted conversion of captured radiant intensity (counts) to temperature values. Image processing techniques are presented to analyze the NIR data for vignetting distortion, best resolution, and image sharpness.