Measurement technology for micro-scale aerodynamics.

Abstract

As micro-technology improves, it may become possible to build flying vehicles at length scales of millimeters, or even microns. Successful design of vehicles at such sizes requires understanding of the fluid mechanics of flight at the micron scale. While biological flight has been studied at these scales, many questions remain to be answered for flight at these scales. Previous work has not determined the limiting scales of continuum aerodynamics for low-speed flight. This study begins with the development of a new scaling law based on boundary layer theory. The laminar boundary layer equations were solved non-dimensionally for slip flow conditions. These results show that a measurable decrease in skin friction, as well as changes in heat transfer, and flow stability, may occur as the boundary layer Knudsen number approaches 0.01. These flow conditions correspond to airfoil chords of up to 100 microns, pressures of 0.1 to 1.0 atmospheres, and velocities from 30 to 100 m/s. Based on this scaling law, specialized wind-tunnel test facilities were designed to operate at scales not previously studied. The novel wind-tunnel allows for independent control of Reynolds and Knudsen numbers on static airfoils. A draw-through, low turbulence, low-pressure wind tunnel with a 1 cm cross section was built and tested. The flow through these facilities is characterized, and recommendations are made for future wind-tunnel development. To allow testing at these scales, micro-scale airfoils, with chords of 100 microns, thicknesses of 5 microns, and a span of 1 cm were fabricated using MEMS fabrication technology. Fabrication of free-standing micro-structures with meso-scale spans and micro-scale cross sections required the development of specialized fabrication processes. These airfoils were integrated with piezoresistive force sensors, allowing measurement of aerodynamic forces. The airfoil structures were successfully released within the tunnel. The actual aerodynamic load on the airfoils in testing exceeded the design loads of the airfoils. It is believed that this is due to vortex shedding during testing. Testing this theory will require development both of new computational techniques, and new test facilities. A road map is provided for the next generation of micro-scale aerodynamics testing.