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Additively Manufactured Wind Tunnel Balances for Propulsive Force Measurement

Propulsive forces and moments during powered descent are not understood well enough to design an entry, decent, and landing vehicle with high confidence using solely computational fluid dynamics modelling (CFD). Therefore, wind tunnel testing is required to quantify uncertainties in computational modeling and simulation. Wind tunnel balances are structural, high-precision, multi-axis force transducers that provide direct measurement of these aerodynamic forces and moments, however their complex designs make them costly and time consuming to produce and approaches used to manufacture them have not changed significantly since the 1960s. This work demonstrates that additive manufacturing (AM) can be used to manufacture wind tunnel balances with significantly reduced fabrication time and expense. Moreover, the design flexibility afforded by the additive manufacturing process has the potential to enable new capabilities with respect to measuring propulsion forces during entry, decent, and landing testing. Here we present two novel balance designs enabled by AM. One will provide direct measurement of aerodynamic interference forces and moments on powered descent models (retropropulsion forces) to support CFD validation and further development of Mars human landing vehicle concepts. The second design will be used to characterize a reaction control system during entry descent and landing testing over a wide Mach number range.

Wind tunnel balance↗
NASA NTRS2015

Additive Manufacturing and Characterization of Ultem Polymers and Composites

The objective of this project was to conduct additive manufacturing to produce aircraft engine components by Fused Deposition Modeling (FDM), using commercially available polyetherimides - Ultem 9085 and experimental Ultem 1000 mixed with 10 percent chopped carbon fiber. A property comparison between FDM-printed and injection-molded coupons for Ultem 9085, Ultem 1000 resin and the fiber-filled composite Ultem 1000 was carried out. Furthermore, an acoustic liner was printed from Ultem 9085 simulating conventional honeycomb structured liners and tested in a wind tunnel. Composite compressor inlet guide vanes were also printed using fiber-filled Ultem 1000 filaments and tested in a cascade rig. The fiber-filled Ultem 1000 filaments and composite vanes were characterized by scanning electron microscope (SEM) and acid digestion to determine the porosity of FDM-printed articles which ranged from 25-31 percent. Coupons of Ultem 9085 and experimental Ultem 1000 composites were tested at room temperature and 400 degrees Fahrenheit to evaluate their corresponding mechanical properties.

Polymers↗
NASA NTRS2010

Unified Application of Vapor Screen Flow Visualization and Pressure Sensitive Paint Measurement Techniques to Vortex- and Shock Wave-Dominated Flow Fields

Laser vapor screen (LVS) flow visualization and pressure sensitive paint (PSP) techniques were applied in a unified approach to wind tunnel testing of slender wing and missile configurations dominated by vortex flows and shock waves at subsonic, transonic, and supersonic speeds. The off-surface cross-flow patterns using the LVS technique were combined with global PSP surface static pressure mappings to characterize the leading-edge vortices and shock waves that coexist and interact at high angles of attack. The synthesis of LVS and PSP techniques was also effective in identifying the significant effects of passive surface porosity and the presence of vertical tail surfaces on the flow topologies. An overview is given of LVS and PSP applications in selected experiments on small-scale models of generic slender wing and missile configurations in the NASA Langley Research Center (NASA LaRC) Unitary Plan Wind Tunnel (UPWT) and 8-Foot Transonic Pressure Tunnel (8-Foot TPT).

Erickson, Gary E.↗
NASA NTRS1996

Analysis of Flowfields over Four-Engine DC-X Rockets

The objective of this study is to validate a computational methodology for the aerodynamic performance of an advanced conical launch vehicle configuration. The computational methodology is based on a three-dimensional, viscous flow, pressure-based computational fluid dynamics formulation. Both wind-tunnel and ascent flight-test data are used for validation. Emphasis is placed on multiple-engine power-on effects. Computational characterization of the base drag in the critical subsonic regime is the focus of the validation effort; until recently, almost no multiple-engine data existed for a conical launch vehicle configuration. Parametric studies using high-order difference schemes are performed for the cold-flow tests, whereas grid studies are conducted for the flight tests. The computed vehicle axial force coefficients, forebody, aftbody, and base surface pressures compare favorably with those of tests. The results demonstrate that with adequate grid density and proper distribution, a high-order difference scheme, finite rate afterburning kinetics to model the plume chemistry, and a suitable turbulence model to describe separated flows, plume/air mixing, and boundary layers, computational fluid dynamics is a tool that can be used to predict the low-speed aerodynamic performance for rocket design and operations.

Wang, Ten-See↗
NASA NTRS2018

Mid-Fidelity Computational Fluid Dynamics Analysis of the Elytron 4S UAV Concept

The Elytron 4S Unmanned Aerial Vehicle (UAV) Concept was developed to combine the advantages of fixed- and rotary-wing technology. The 4S Concept is a box-wing configuration with rotors mounted on a centrally located tiltwing. The UAV is intended to be capable of both conventional takeoff and landing (CTOL) and vertical takeoff and landing (VTOL), and is envisioned to excel in UAV performance because of the combined efficiency of fixed-wing aircraft and the hover and VTOL capabilities of regular drones or quadcopters. A mid-fidelity Unsteady Reynolds-Averaged Navier-Stokes (URANS) approach using Rotorcraft CFD (RotCFD) is performed to analyze and characterize the performance of the aircraft. The flow field is coupled with a rotor model based on blade-element momentum theory to model the 4S UAV rotors. Turbulence is modeled using a realizable k- turbulence model with special wall function. The code is used to generate aerodynamic forces and moments on the body at cruise conditions, and during VTOL. The results and their uncertainties are characterized, and an angle- of-attack and sideslip sweep are computed, both with and without rotors on. Simulations are compared with the wind tunnel tests in the 7- by 10-Foot U.S. Army Wind Tunnel at NASA Ames Research Center, performed in 2017. Results show promising comparison with experimental data, despite a late change in rotor size and rudder size of the physical model that cause the expected deviations from the simulation. A slight change in the net thrust value, when rotors are modeled, is observed because of the rotor diameter increase on the physical model. A noticeable difference in the directional stability was observed because of the increased rudder surface and added strakes. These changes were implemented to improve on the design as simulated, which is observed in the results. The simulation results paved the way to the first successful flight of the UAV Concept.

Koning, Witold J. K.↗
NASA NTRS2008

Unified Application Vapor Screen Flow Visualization and Pressure Sensitive Paint Measurement Techniques to Vortex- and Shock Wave-Dominated Flow Fields

Laser vapor screen (LVS) flow visualization and pressure sensitive paint (PSP) techniques were applied in a unified approach to wind tunnel testing of slender wing and missile configurations dominated by vortex flows and shock waves at subsonic, transonic, and supersonic speeds. The off-surface cross-flow patterns using the LVS technique were combined with global PSP surface static pressure mappings to characterize the leading-edge vortices and shock waves that coexist and interact at high angles of attack (alpha). The synthesis of LVS and PSP techniques was also effective in identifying the significant effects of passive surface porosity and the presence of vertical tail surfaces on the flow topologies. An overview is given of LVS and PSP applications in selected experiments on small-scale models of generic slender wing and missile configurations in the NASA Langley Research Center (NASA LaRC) Unitary Plan Wind Tunnel (UPWT) and 8-Foot Transonic Pressure Tunnel (8-Foot TPT).

Erickson, Gary E.↗
NASA NTRS2002

Wake Closure Characteristics and Afterbody Heating on a Mars Sample Return Orbiter

Aeroheating wind-tunnel tests were conducted on a 0.028 scale model of an orbiter concept considered for a possible Mars sample return mission. The primary experimental objectives were to characterize hypersonic near wake closure and determine if shear layer impingement would occur on the proposed orbiter afterbody at incidence angles necessary for a Martian aerocapture maneuver. Global heat transfer mappings, surface streamline patterns, and shock shapes were obtained in the NASA Langley 20-Inch Mach 6 Air and CF4 Tunnels for post-normal shock Reynolds numbers (based on forebody diameter) ranging from 1,400 to 415,000, angles of attack ranging from -5 to 10 degrees at 0, 3, and 6 degree sideslip, and normal-shock density ratios of 5 and 12. Laminar, transitional, and turbulent shear layer impingement on the cylindrical afterbody was inferred from the measurements and resulted in a localized heating maximum that ranged from 40 to 75 percent of the reference forebody stagnation point heating. Comparison of laminar heating prediction to experimental measurement along the orbiter afterbody highlight grid alignment challenges associated with numerical simulation of three- dimensional separated wake flows. Predicted values of a continuum breakdown parameter revealed significant regions of non-continuum flow downstream of the flow separation at the MSRO shoulder and in the region of the reattachment shock on the afterbody. The presence of these regions suggest that the Navier-Stokes predictions at the laminar wind-tunnel condition may encounter errors in the numerical calculation of the wake shear layer development and impingement due to non-continuum effects.

Horvath, Thomas J.↗
NASA NTRS1986

Measurements of a turbulent horseshoe vortex formed around a cylinder

An experimental investigation was conducted to characterize a symmetrical horseshoe vortex system in front of and around a single large-diameter right cylinder centered between the sidewalls of a wind tunnel. Surface flow visualization and surface static pressure measurements as well as extensive mean velocity and pressure measurements in and around the vortex system were acquired. The results lend new insight into the formation and development of the vortex system. Contrary to what has been assumed previously, a strong vortex was not identified in the streamwise plane of symmetry, but started a significant angular distance away from it. Rather than the multiple vortex systems reported by others, only a single primary vortex and saddle point were found. The scale of the separation process at the saddle point was much smaller than the scale of the approaching boundary layer thickness. Results of the present study not only shed light on such phenomena as the nonsymmetrical endwall flow in axial turbomachinery but can also be used as a test case for three-dimensional computational fluid mechanics computer codes.

Eckerle, W. A.↗
NASA NTRS1994

Field verification of the wind tunnel coefficients

Accurate information about wind action on antennas is required for reliable prediction of antenna pointing errors in windy weather and for the design of an antenna controller with wind disturbance rejection properties. The wind tunnel data obtained 3 years ago using a scaled antenna model serves as an antenna industry standard, frequently used for the first purpose. The accuracy of the wind tunnel data has often been challenged, since they have not yet been tested in a field environment (full-aized antenna, real wind, actual terrain, etc.). The purpose of this investigation was to obtain selected field measurements and compare them with the available wind tunnel data. For this purpose, wind steady-state torques of the DSS-13 antenna were measured, and dimensionless wind torque coefficients were obtained for a variety of yaw and elevation angles. The results showed that the differences between the wind tunnel torque coefficients and the field torque coefficients were less than 10 percent of their values. The wind-gusting action on the antenna was characterized by the power spectra of the antenna encoder and the antenna torques. The spectra showed that wind gusting primarily affects the antenna principal modes.

Gawronski, W. K.↗
NASA NTRS2015

Open Rotor Noise Shielding by Blended-Wing-Body Aircraft

This paper presents an analysis of open rotor noise shielding by Blended Wing Body (BWB) aircraft by using model scale test data acquired in the Boeing Low Speed Aeroacoustic Facility (LSAF) with a legacy F7/A7 rotor model and a simplified BWB platform. The objective of the analysis is the understanding of the shielding features of the BWB and the method of application of the shielding data for noise studies of BWB aircraft with open rotor propulsion. By studying the directivity patterns of individual tones, it is shown that though the tonal energy distribution and the spectral content of the wind tunnel test model, and thus its total noise, may differ from those of more advanced rotor designs, the individual tones follow directivity patterns that characterize far field radiations of modern open rotors, ensuring the validity of the use of this shielding data. Thus, open rotor tonal noise shielding should be categorized into front rotor tones, aft rotor tones and interaction tones, not only because of the different directivities of the three groups of tones, but also due to the differences in their source locations and coherence features, which make the respective shielding characteristics of the three groups of tones distinctly different from each other. To reveal the parametric trends of the BWB shielding effects, results are presented with variations in frequency, far field emission angle, rotor operational condition, engine installation geometry, and local airframe features. These results prepare the way for the development of parametric models for the shielding effects in prediction tools.

Guo, Yueping↗
NASA NTRS2015

A Fully Nonmetallic Gas Turbine Engine Enabled by Additive Manufacturing, Part II: Additive Manufacturing and Characterization of Polymer Composites

This publication is the second part of the three part report of the project entitled "A Fully Nonmetallic Gas Turbine Engine Enabled by Additive Manufacturing" funded by NASA Aeronautics Research Institute (NARI). The objective of this project was to conduct additive manufacturing to produce aircraft engine components by Fused Deposition Modeling (FDM), using commercially available polyetherimides-Ultem 9085 and experimental Ultem 1000 mixed with 10% chopped carbon fiber. A property comparison between FDM-printed and injection molded coupons for Ultem 9085, Ultem 1000 resin and the fiber-filled composite Ultem 1000 was carried out. Furthermore, an acoustic liner was printed from Ultem 9085 simulating conventional honeycomb structured liners and tested in a wind tunnel. Composite compressor inlet guide vanes were also printed using fiber-filled Ultem 1000 filaments and tested in a cascade rig. The fiber-filled Ultem 1000 filaments and composite vanes were characterized by scanning electron microscope (SEM) and acid digestion to determine the porosity of FDM-printed articles which ranged from 25 to 31%. Coupons of Ultem 9085, experimental Ultem 1000 composites and XH6050 resin were tested at room temperature and 400F to evaluate their corresponding mechanical properties. A preliminary modeling was also initiated to predict the mechanical properties of FDM-printed Ultem 9085 coupons in relation to varied raster angles and void contents, using the GRC-developed MAC/GMC program.

Polymer↗
NASA NTRS2005

Diode Laser Sensors for Arc-Jet Characterization

The development and application of tunable diode laser (TDL) absorption sensors to monitor the health and operating conditions in the large-scale 60 MW arc-heated- plasma wind-tunnel at NASA Ames Research Center is reported. The interactive heating facility (THF) produces re-entry flow conditions by expanding the gas heated in a constricted plasma arc-heater to flow at high velocity over a model located in a test cabin. This facility provides the conditions needed to test thermal protective systems for spacecraft re-entering the earth s atmosphere. TDL sensors are developed to monitor gas flows in both the high-temperature constricted flow and the supersonic expansion flow into test cabin. These sensors utilize wavelength-tuned diode lasers to measure absorption transitions of atomic oxygen near 777.2 nm, atomic nitrogen near 856.8 nm, and atomic copper near 793.3 nm. The oxygen and nitrogen sensors measure the population density in exited electronic states of these atoms. The measurements combined with the assumption of local thermal and chemical equilibrium yield gas temperature (typically near 7,000K). The nitrogen and oxygen population temperatures are redundant, and their close agreement provides an important test of the local thermal equilibrium assumption. These temperature sensors provide time-resolved monitors of the operating conditions of the arc-heater and can be used to verify and control the test conditions. An additional TDL sensor was developed to monitor the copper concentration in the arc-heater flow yielding values as high as 13 ppm. Measurements of copper in the flow can identify flow conditions with unacceptably rapid electrode erosion, and hence this sensor provides valuable information needed to schedule maintenance to avoid costly arc-heater failure. TDL sensors were also developed for measurements in the test cabin, where absorption measurements of the populations of argon and molecular nitrogen in excited metastable electronic states established that the number density of these excited species is much lower than estimated using frozen-chemistry approximations. This key finding suggests that in the post-expansion region there is not a significant energy sequestration in electronically excited species. Finally, TDL measurements of atomic potassium seeded into the test cabin flow were used to directly measure the static temperature of the test gas. The results of this study illustrate the high potential of time-resolved TDL measurements for routine and economical sensing of arc-heater health (gas temperature and electrode erosion) as well as the time-resolved test-cabin-flow conditions in front of the model.

Hanson, Ronald K.↗
NASA NTRS1986

Horseshoe vortex formation around a cylinder

An experimental investigation was conducted to characterize a symmetrical horseshoe vortex system in front of and a around a single large-diameter right cylinder centered between the sidewalls of a wind tunnel. Surface flow visualization anad surface static pressure measurements as well as extensive mean velocity and pressure measurements in and around the vortex system were acquired. The results lend new insight into the formation and development of the vortex system. Contrary to what has been assumed previously, a strong vortex was not identified in the streamwise plane of symmetry, but started a significant angular distance away from it. Rather than the multiple vortex systems reported by others, only a single primary vortex and saddle point were found. The scale of the separation process at the saddle point was much smaller than the scale of the approaching bundary layer thickness. Results of the present study not only shed light on such phenomena as the nonsymmetrical endwall flow in axial turbomachinery but can also be used as a test case for three-dimensional computational fluid mechanics computer codes.

Eckerle, W. A.↗
NASA NTRS2010

Numerical Computations of Hypersonic Boundary-Layer over Surface Irregularities

Surface irregularities such as protuberances inside a hypersonic boundary layer may lead to premature transition on the vehicle surface. Early transition in turn causes large localized surface heating that could damage the thermal protection system. Experimental measurements as well as numerical computations aimed at building a knowledge base for transition Reynolds numbers with respect to different protuberance sizes and locations have been actively pursued in recent years. This paper computationally investigates the unsteady wake development behind large isolated cylindrical roughness elements and the scaled wind-tunnel model of the trip used in a recent flight measurement during the reentry of space shuttle Discovery. An unstructured mesh, compressible flow solver based on the space-time conservation element, solution element (CESE) method is used to perform time-accurate Navier-Stokes calculations for the flow past a roughness element under several wind-tunnel conditions. For a cylindrical roughness element with a height to the boundary-layer thickness ratio from 0.8 to 2.5, the wake flow is characterized by a mushroom-shaped centerline streak and horse-shoe vortices. While time-accurate solutions converged to a steady-state for a ratio of 0.8, strong flow unsteadiness is present for a ratio of 1.3 and 2.5. Instability waves marked by distinct disturbance frequencies were found in the latter two cases. Both the centerline streak and the horse-shoe vortices become unstable downstream. The oscillatory vortices eventually reach an early breakdown stage for the largest roughness element. Spectral analyses in conjunction with the computed root mean square variations suggest that the source of the unsteadiness and instability waves in the wake region may be traced back to possible absolute instability in the front-side separation region.

Chang, Chau-Lyan↗
NASA NTRS2010

Control Activity in Support of NASA Turbine Based Combined Cycle (TBCC) Research

Control research for a Turbine Based Combined Cycle (TBCC) propulsion system is the current focus of the Hypersonic Guidance, Navigation, and Control (GN&C) discipline team. The ongoing work at the NASA Glenn Research Center (GRC) supports the Hypersonic GN&C effort in developing tools to aid the design of control algorithms to manage a TBCC airbreathing propulsion system during a critical operating period. The critical operating period being addressed in this paper is the span when the propulsion system transitions from one cycle to another, referred to as mode transition. One such tool, that is a basic need for control system design activities, is computational models (hereto forth referred to as models) of the propulsion system. The models of interest for designing and testing controllers are Control Development Models (CDMs) and Control Validation Models (CVMs). CDMs and CVMs are needed for each of the following propulsion system elements: inlet, turbine engine, ram/scram dual-mode combustor, and nozzle. This paper presents an overall architecture for a TBCC propulsion system model that includes all of the propulsion system elements. Efforts are under way, focusing on one of the propulsion system elements, to develop CDMs and CVMs for a TBCC propulsion system inlet. The TBCC inlet aerodynamic design being modeled is that of the Combined-Cycle Engine (CCE) Testbed. The CCE Testbed is a large-scale model of an aerodynamic design that was verified in a small-scale screening experiment. The modeling approach includes employing existing state-of-the-art simulation codes, developing new dynamic simulations, and performing system identification experiments on the hardware in the NASA GRC 10 by10-Foot Supersonic Wind Tunnel. The developed CDMs and CVMs will be available for control studies prior to hardware buildup. The system identification experiments on the CCE Testbed will characterize the necessary dynamics to be represented in CDMs for control design. These system identification models will also be the reference models to validate the CDM and CVM models. Validated models will give value to the tools used to develop the models.

Stueber, Thomas J.↗
NASA NTRS2000

Development of a Flush Airdata Sensing System on a Sharp-Nosed Vehicle for Flight at Mach 3 to 8

NASA Dryden Flight Research Center has developed a flush airdata sensing (FADS) system on a sharp-nosed, wedge-shaped vehicle. This paper details the design and calibration of a real-time angle-of-attack estimation scheme developed to meet the onboard airdata measurement requirements for a research vehicle equipped with a supersonic-combustion ramjet engine. The FADS system has been designed to perform in flights at speeds between Mach 3 and Mach 8 and at angles of attack between -6 deg. and 12 deg. The description of the FADS architecture includes port layout, pneumatic design, and hardware integration. Predictive models of static and dynamic performance are compared with wind-tunnel results across the Mach and angle-of-attack range. Results indicate that static angle-of-attack accuracy and pneumatic lag can be adequately characterized and incorporated into a real-time algorithm.

Davis, Mark C.↗
NASA NTRS2000

Development of a Flush Airdata Sensing System on a Sharp-Nosed Vehicle for Flight at Mach 3 to 8

NASA Dryden Flight Research Center has developed a flush airdata sensing (FADS) system on a sharp-nosed, wedge-shaped vehicle. This paper details the design and calibration of a real-time angle-of-attack estimation scheme developed to meet the onboard airdata measurement requirements for a research vehicle equipped with a supersonic-combustion ramjet engine. The FADS system has been designed to perform in flights at Mach 3-8 and at -6 deg - 12 deg angle of attack. The description of the FADS architecture includes port layout, pneumatic design, and hardware integration. Predictive models of static and dynamic performance are compared with wind-tunnel results across the Mach and angle-of-attack range. Results indicate that static angle-of-attack accuracy and pneumatic lag can be adequately characterized and incorporated into a real-time algorithm.

Davis, Mark C.↗