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Evaluation of NCAR Icing/SLD Forecasts, Tools and Techniques Used During The 1998 NASA SLD Flight Season

Supercooled Large Droplet (SLD) icing conditions were implicated in at least one recent aircraft crash, and have been associated with other aircraft incidents. Inflight encounters with SLD can result in ice accreting on unprotected areas of the wing where it can not be removed. Because this ice can adversely affect flight characteristics of some aircraft, there has been concern about flight safety in these conditions. The FAA held a conference on in-flight icing in 1996 where the state of knowledge concerning SLD was explored. One outcome of these meetings was an identified need to acquire SLD flight research data, particularly in the Great Lakes Region. The flight research data was needed by the FAA to develop a better understanding of the meteorological characteristics associated with SLD and facilitate an assessment of existing aircraft icing certification regulations with respect to SLD. In response to this need, NASA, the Federal Aviation Administration (FAA), and the National Center for Atmospheric Research (NCAR) conducted a cooperative icing flight research program to acquire SLD flight research data. The NASA Glenn Research Center's Twin Otter icing research aircraft was flown throughout the Great Lakes region during the winters of 1996-97 and 1997-98 to acquire SLD icing and meteorological data. The NASA Twin Otter was instrumented to measure cloud microphysical properties (particle size, LWC (Liquid Water Content), temperature, etc.), capture images of wing and tail ice accretion, and then record the resultant effect on aircraft performance due to the ice accretion. A satellite telephone link enabled the researchers onboard the Twin Otter to communicate with NCAR meteorologists. who provided real-time guidance into SLD icing conditions. NCAR meteorologists also provided preflight SLD weather forecasts that were used to plan the research flights, and served as on-board researchers. This document contains an evaluation of the tools and techniques NCAR forecasters used to predict the location of SLD icing conditions during the winter of 1997-1998. The objectives of this report are to: (1) assess the tools used to forecast in-flight icing. (2) assess the success/failure rate of the forecasts, and (3) discuss suggested changes to forecast techniques.

Bernstein, Ben C.↗

COMDES-MELT: A Turbofan Engine Icing Risk Analysis Tool, User’s Manual

The computational tool COMDES-MELT was developed to predict the susceptibility of turbofan engines to ice accretion when flying in an ice crystal environment. COMDES-MELT is a first-generation computational tool that can estimate the conditions at which the accretion of ice can occur, location within the turbofan engine compression system, and at which engine operating points within the flight trajectory. This is accomplished by tracking the parameters of static wet bulb temperature, ice particle melt ratio, and the ice-water to airflow rates ratio as ice crystals are ingested into the engine compression system. It has been used successfully to predict engine operating points for simulation in an altitude wind tunnel with ice crystal ingestion. These engine tests occur in a simulated ice crystal cloud environment. This predictive analysis has been used to generate the test matrix in preparation for tests in the Propulsion Systems Laboratory, an altitude test facility at the NASA Glenn Research Center. Furthermore, due to the speed of the code during an engine icing test, adjustments to the test matrix can be provided to the test engineer in real time to focus on a particular area of ice accretion susceptibility. The use of the COMDES-MELT code will be examined in this manual.

Turbofan engine↗

Laser Sheet Flow Visualization Developed for Lewis' Icing Research Tunnel

A new flow-visualization technique has been developed for use in the NASA Lewis Research Center's Icing Research Tunnel (IRT). This technique uses a sheet of light shining across the wind tunnel to illuminate a mist of water droplets in the air and display any organized flow patterns. Since the IRT already has the special water spray system required for aircraft icing experiments, no special visualization seeding material is required. The system has been used to visualize the changes in tip and leading edge vortices caused by ice accretion. Because the IRT's icing spray is used as part of the visualization technique, changes in the flow patterns about a wing can be observed and measured during the ice accretion process.

Source record↗

Numerical simulation of ice growth on a MS-317 swept wing geometry

An effort to develop a 3-D ice accretion modeling method was initiated. This first step towards creation of a complete aircraft icing simulation code builds on previously developed methods for calculating 3-D flow fields and particle trajectories combined with a 2-D ice accretion calculation along coordinate locations corresponding to streamlines. The types of calculations necessary to predict 3-D ice accretion is demonstrated. Results of calculations using 3-D method for a MS-317 swept wing geometry are projected onto a 2-D plane parallel to the free stream direction and compared to experimental results for the same geometry. It is anticipated that many modifications will be made to this approach, however this effort will lay the groundwork for future modeling efforts. Results indicate that rime ice shapes indicate a difficulty in accurately calculating the ice shape in the runback region.

Potapczuk, M. G.↗

Numerical simulation of ice growth on a MS-317 swept wing geometry

An effort to develop a 3-D ice accretion modeling method was initiated. This first step towards creation of a complete aircraft icing simulation code builds on previously developed methods for calculating 3-D flow fields and particle trajectories combined with a 2-D ice accretion calculation along coordinate locations corresponding to streamlines. The types of calculations necessary to predict three-dimensional ice accretion is demonstrated. Results of calculations using 3-D method for a MS-317 swept wing geometry are projected onto a 2-D plane parallel to the free stream direction and compared to experimental results for the same geometry. It is anticipated that many modifications will be made to this approach, however, this effort will lay the groundwork for future modeling efforts. Results indicate that rime ice shapes indicate a difficulty in accurately calculating the ice shape in the runback region.

Potapczuk, M. G.↗

Ice Shape Analysis of an eVTOL Propeller in Forward Flight at the NASA Glenn Icing Research Tunnel

Advanced Air Mobility (AAM) introduces many novel electric vertical takeoff and landing (eVTOL) aircraft configurations for which the effect of icing is not well understood. While icing computational tools have often aided in the design and certification of conventional aircraft, experimental data is needed to support the development and validation of such tools for eVTOL applications. To investigate the icing phenomenon relevant to eVTOL aircraft, NASA Glenn Research Center developed a general-purpose propeller test stand for conducting fundamental icing research on electrically driven propellers in the Icing Research Tunnel (IRT). A 10-day test entry in the IRT was completed in March, 2023, with the goal of generating ice accretions on a non-proprietary propeller geometry under well-characterized conditions. Three carbon fiber propellers of diameters 0.610, 0.711, and 0.914 m (24, 28, and 36 in) were used during the test. Various parametric sweeps of cloud and operating conditions were performed to evaluate the sensitivity of the parameters on the resulting ice accretion characteristics such as ice thickness, mass, location (impingement limits), and type (glaze vs rime). Ice shapes were reviewed for their repeatability, correctness of trends, and sensitivity to parameter variations. The data from the test is being used to support the development of the ice accretion solver, GlennICE.

Icing↗

Ice Shape Analysis of an eVTOL Propeller in Forward Flight at the NASA Glenn Icing Research Tunnel

Advanced Air Mobility (AAM) introduces many novel electric vertical takeoff and landing (eVTOL) aircraft configurations for which the effect of icing is not well understood. While icing computational tools have often aided in the design and certification of conventional aircraft, experimental data is needed to support the development and validation of such tools for eVTOL applications. To investigate the icing phenomenon relevant to eVTOL aircraft, NASA Glenn Research Center developed a general-purpose propeller test stand for conducting fundamental icing research on electrically driven propellers in the Icing Research Tunnel (IRT). A 10-day test entry in the IRT was completed in March, 2023, with the goal of generating ice accretions on a non-proprietary propeller geometry under well-characterized conditions. Three carbon fiber propellers of diameters 0.610, 0.711, and 0.914 m (24, 28, and 36 in) were used during the test. Various parametric sweeps of cloud and operating conditions were performed to evaluate the sensitivity of the parameters on the resulting ice accretion characteristics such as ice thickness, mass, location (impingement limits), and type (glaze vs rime). Ice shapes were reviewed for their repeatability, correctness of trends, and sensitivity to parameter variations. The data from the test is being used to support the development of the ice accretion solver, GlennICE.

Icing↗

Method to Generate Full-Span Ice Shape on Swept Wing Using Icing Tunnel Data

There is a collaborative research program by NASA, FAA, ONERA, and university partners to improve the fidelity of experimental and computational simulation methods for swept-wing ice accretion formulations and resultant aerodynamic effects on large transport aircraft. This research utilizes a 65 scale Common Research Model as the baseline configuration. In order to generate the ice shapes for the aerodynamic testing, ice-accretion testing will be conducted in the NASA Icing Research Tunnel utilizing hybrid model from the 20, 64, and 83 spanwise locations. The models will have full-scale leading edges with truncated chord in order to fit the IRT test section. The ice shapes from the IRT tests will be digitized using a commercially available articulated-arm 3D laser scanning system. The methodology to acquire 3D ice shapes using a laser scanner was developed and validated in a previous research effort. Each of these models will yield a 1.5ft span of ice than can be used. However, a full-span ice accretion will require 75 ft span of ice. This means there will be large gaps between these spanwise ice sections that must be filled, while maintaining all of the important aerodynamic features. A method was developed to generate a full-span ice shape from the three 1.5 ft span ice shapes from the three models.

swept↗

Progress toward the development of an airfoil icing analysis capability

The NASA-Lewis aircraft icing analysis program is composed of three major sub-programs. These sub-programs are ice accretion simulation, performance degradation evaluation, and ice protection system evaluation. These topics cover all areas of concern related to the simulation of aircraft icing and its consequences. The motivation for these activities is twofold, reduction of time and effort required in experimental programs and the ability to provide reliable information for aircraft certification in icing, over the complete range of environmental conditions. In addition to the analytical activities associated with development of these codes, several experimental programs are underway to provide verification information for existing codes. These experimental programs are also used to investigate the physical processes associated with ice accretion and removal for improvement of present analytical models. The NASA-Lewis icing analysis program is thus striving to provide a full range of analytical tools necessary for evaluation of the consequences of icing and of ice protection systems.

Potapczuk, Mark G.↗

Heat Transfer Measurements on Surfaces with Natural Ice Castings and Modeled Roughness

An experimental method is described to measure and compare the convective heat transfer coefficient of natural and simulated ice accretion roughness and to provide a rational means for determining accretion-related enhanced heat transfer coefficients. The natural ice accretion roughness was a sample casting made from accretions at the NASA Lewis Icing Research Tunnel (IRT). One of these castings was modeled using a Spectral Estimation Technique (SET) to produce three roughness elements patterns that simulate the actual accretion. All four samples were tested in a flat-plate boundary layer at angle of attack in a "dry" wind tunnel test. The convective heat transfer coefficient was measured using infrared thermography. It is shown that, dispite some problems in the current data set, the method does show considerable promise in determining roughness-induced heat transfer coefficients, and that, in addition to the roughness height and spacing in the flow direction, the concentration and spacing of elements in the spanwise direction are important parameters.

Breuer, Kenneth S.↗

Overview of Icing Physics Relevant to Scaling

An understanding of icing physics is required for the development of both scaling methods and ice-accretion prediction codes. This paper gives an overview of our present understanding of the important physical processes and the associated similarity parameters that determine the shape of Appendix C ice accretions. For many years it has been recognized that ice accretion processes depend on flow effects over the model, on droplet trajectories, on the rate of water collection and time of exposure, and, for glaze ice, on a heat balance. For scaling applications, equations describing these events have been based on analyses at the stagnation line of the model and have resulted in the identification of several non-dimensional similarity parameters. The parameters include the modified inertia parameter of the water drop, the accumulation parameter and the freezing fraction. Other parameters dealing with the leading edge heat balance have also been used for convenience. By equating scale expressions for these parameters to the values to be simulated a set of equations is produced which can be solved for the scale test conditions. Studies in the past few years have shown that at least one parameter in addition to those mentioned above is needed to describe surface-water effects, and some of the traditional parameters may not be as significant as once thought. Insight into the importance of each parameter, and the physical processes it represents, can be made by viewing whether ice shapes change, and the extent of the change, when each parameter is varied. Experimental evidence is presented to establish the importance of each of the traditionally used parameters and to identify the possible form of a new similarity parameter to be used for scaling.

Anderson, David N.↗

Convective Enhancement of Icing Roughness Elements in Stagnation Region Flows

To improve existing ice accretion simulation codes, more data regarding ice roughness and its effects on convective heat transfer are required. To build on existing research on this topic, this study used the Vertical Icing Studies Tunnel (VIST) at NASA Glenn Research to model realistic ice roughness in the stagnation region of a NACA 0012 airfoil. Using the VIST, a test plate representing the leading 2% chord of the airfoil was subjected to flows of 7.62 m/s (25 ft/s), 12.19 m/s (40 ft/s), and 16.76 m/s (55 ft/s). The test plate was fitted with 3 surfaces, each with a different representation of ice roughness: 1) a control surface with no ice roughness, 2) a surface with ice roughness with element height scaled by 10x and streamwise rough zone width from the stagnation point scaled by 10x, and 3) a surface with ice roughness with element height scaled by 10x and streamwise rough zone width from the stagnation point scaled by 25x. Temperature data from the tests were recorded using an infrared camera and thermocouples imbedded in the test plate. From the temperature data, a convective heat transfer coefficient map was created for each case. Additional testing was also performed to validate the VIST's flow quality. These tests included five-hole probe and hot-wire probe velocity traces to provide flow visualization and to study boundary layer formation on the various test surfaces. The knowledge gained during the experiments will help improve ice accretion codes by providing heat transfer coefficient validation data and by providing flow visualization data helping understand current and future experiments performed in the VIST.

Icing↗

Observations on the Growth of Roughness Elements Into Icing Feathers

This work presents the results of an experiment conducted in the Icing Research Tunnel at NASA Glenn Research Center to understand the process by which icing feathers are formed in the initial stages of ice accretion formation on swept wings. Close-up photographic data were taken on an aluminum NACA 0012 swept wing tip airfoil. Two types of photographic data were obtained: time sequence close-up photographic data during the run and close-up photographic data of the ice accretion at the end of each run. Icing runs were conducted for short ice accretion times from 10 to 180 sec. The time sequence close-up photographic data was used to study the process frame by frame and to create movies of how the process developed. The movies confirmed that at glaze icing conditions in the attachment line area icing feathers develop from roughness elements. The close-up photographic data at the end of each run showed that roughness elements change into a pointed shape with an upstream facet and join on the side with other elements having the same change to form ridges with pointed shape and upstream facet. The ridges develop into feathers when the upstream facet grows away to form the stem of the feather. The ridges and their growth into feathers were observed to form the initial scallop tips present in complete scallops.

Vargas, Mario↗

Comparison of Bimodal Ice Shapes on Full-Chord and Hybrid CRM Midspan Models

An ice shape database has been created to document ice accretions on a full-chord length and hybrid versions of a 65 percent scale size of the mid-span section of the Common Research Model resulting from an exposure to a Super-cooled Large Drop (SLD) icing cloud with a bimodal drop size distribution. The ice shapes created were documented with photographs, laser scanned surface measurements over a section of the model span, and measurement of the ice mass over the same section of each ice accretion. Drop distribution effects were evaluated by using the same IRT icing conditions except with either monomodal or bimodal drop distributions. Ice shapes resulting from the bimodal distribution as well as from monomodal distributions of identical cloud droplet Median Volume Diameter (MVD) were obtained and compared. Results indicated that the ice shapes resulting from the monomodal and bimodal drop size distributions have similar 2D Maximum Combined Cross Section, or MCCS, ice shape around the model leading edge region and equivalent ice mass measurement per unit span to within the IRT SLD cloud calibration uncertainty, as expected with this approach, but the bimodal distributions have distinctly larger ice feathers that extended further back on the chord of the model. For most test conditions, the overall size and shape of the main ice accretions compared well between the full-chord and hybrid models

Icing , Simulation, Validation↗

Comparison of Bimodal Ice Shapes on Full-Chord and Hybrid CRM Midspan Models

An ice shape database has been created to document ice accretions on a full-chord length and hybrid versions of a 65 percent scale size of the mid-span section of the Common Research Model resulting from an exposure to a Super-cooled Large Drop (SLD) icing cloud with a bimodal drop size distribution. The ice shapes created were documented with photographs, laser scanned surface measurements over a section of the model span, and measurement of the ice mass over the same section of each ice accretion. Drop distribution effects were evaluated by using the same IRT icing conditions except with either monomodal or bimodal drop distributions. Ice shapes resulting from the bimodal distribution as well as from monomodal distributions of identical cloud droplet Median Volume Diameter (MVD) were obtained and compared. Results indicated that the ice shapes resulting from the monomodal and bimodal drop size distributions have similar 2D Maximum Combined Cross Section, or MCCS, ice shape around the model leading edge region and equivalent ice mass measurement per unit span to within the IRT SLD cloud calibration uncertainty, as expected with this approach, but the bimodal distributions have distinctly larger ice feathers that extended further back on the chord of the model. For most test conditions, the overall size and shape of the main ice accretions compared well between the full-chord and hybrid models.

Icing↗

Comparison of Bimodal Ice Shapes on Full-Chord and Hybrid CRM Midspan Models

An ice shape database has been created to document ice accretions on a full-chord length and hybrid versions of a 65 percent scale size of the mid-span section of the Common Research Model resulting from an exposure to a Super-cooled Large Drop (SLD) icing cloud with a bimodal drop size distribution. The ice shapes created were documented with photographs, laser scanned surface measurements over a section of the model span, and measurement of the ice mass over the same section of each ice accretion. Drop distribution effects were evaluated by using the same IRT icing conditions except with either monomodal or bimodal drop distributions. Ice shapes resulting from the bimodal distribution as well as from monomodal distributions of identical cloud droplet Median Volume Diameter (MVD) were obtained and compared. Results indicated that the ice shapes resulting from the monomodal and bimodal drop size distributions have similar 2D Maximum Combined Cross Section, or MCCS, ice shape around the model leading edge region and equivalent ice mass measurement per unit span to within the IRT SLD cloud calibration uncertainty, as expected with this approach, but the bimodal distributions have distinctly larger ice feathers that extended further back on the chord of the model. For most test conditions, the overall size and shape of the main ice accretions compared well between the full-chord and hybrid models.

Icing↗

The UH-1H helicopter icing flight test program: An overview

An ongoing joint NASA/Army program to study the effects of ice accretion on unprotected helicopter rotor aerodynamic performance is discussed. This program integrates flight testing, wind tunnel testing, and analytical modeling. Results are discussed for helicopter flight testing in the Canadian NRC hover spray rig facility to measure rotor aero performance degradation and document rotor ice accretion characteristics. The results of dry wind tunnel testing of airfoil sections with artificial ice accretions and predictions of rotor performance degradation using available rotor performance codes and the wind tunnel data are presented. An alternative approach to conducting future helicopter icing flight programs is discussed.

Shaw, R. J.↗

The UH-1H helicopter icing flight test program - An overview

An ongoing joint NASA/Army program to study the effects of ice accretion on unprotected helicopter rotor aerodynamic performance is discussed. This program integrates flight testing, wind tunnel testing, and analytical modeling. Results are discussed for helicopter flight testing in the Canadian NRC hover spray rig facility to measure rotor aero performance degradation and document rotor ice accretion characteristics. The results of dry wind tunnel testing of airfoil sections with artificial ice accretions and predictions of rotor performance degradation using available rotor performance codes and the wind tunnel data are presented. An alternative approach to conducting future helicopter icing flight programs is discussed.

Shaw, R. J.↗