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High-Speed and High-Temperature Calorimetric Solid-State Thermal Mass Flow Sensor for Aerospace Application: A

Lucas Ribeiro1, Osamu Saotome1, Roberto d'Amore1

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This study enhances aircraft Air Data Systems (ADS) with a high-temperature thermal mass flow sensor (TMFS). Optimizing sensor design significantly improves accuracy for reliable flight operations.

Keywords:
Air Data SystemMEMSTMFScalorimetricflow sensorsensitivity

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Area of Science:

  • Aerospace Engineering
  • Sensor Technology
  • Thermodynamics

Background:

  • Pitot tubes in aircraft Air Data Systems (ADS) are vulnerable to ice accretion, leading to system failure and loss of critical flight protections.
  • Existing thermal mass flow sensors (TMFS) require optimization for high-speed, high-temperature environments.
  • Enhancing TMFS reliability is crucial for maintaining aircraft safety.

Purpose of the Study:

  • To numerically assess the sensitivity of a high-speed, high-temperature calorimetric solid-state TMFS.
  • To investigate the impact of heater-sensor distance and thermal barriers on TMFS performance.
  • To improve the reliability of aircraft ADS against environmental hazards like icing.

Main Methods:

  • Numerical assessment of a calorimetric solid-state TMFS operating at 573.15 K (300 °C) and measuring airspeeds up to 265 m/s.
  • Parametric study on the effect of varying the distance between the heater and thermal sensors.
  • Evaluation of the performance enhancement achieved by incorporating a Parylene-N thermal barrier.

Main Results:

  • Increasing the heater-sensor distance from 0.1 mm to 0.6 mm improved temperature sensitivity by up to 80% and airspeed sensitivity by up to 100%.
  • The addition of a Parylene-N thermal barrier resulted in a nearly 6-fold improvement in sensitivity for both temperature and airspeed variations.
  • The proposed TMFS design shows significant potential for enhancing ADS reliability.

Conclusions:

  • Optimizing the physical configuration of TMFS, specifically heater-sensor distance and thermal insulation, dramatically enhances sensor sensitivity.
  • The developed TMFS offers a robust solution to mitigate the risks associated with pitot tube icing in aircraft.
  • This research contributes to the development of more reliable and safer aviation systems.