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Analysis of the performance of the drive system and diffuser of the Langley unitary plan wind tunnel

A broad program was initiated at the Langley Research Center in 1973 to reduce the energy consumption of the laboratory. As a part of this program, the performance characteristics of the Unitary Plan Wind Tunnel were reexamined to determine if potential methods for incresing the operating efficiencies of the tunnel could be formulated. The results of that study are summarized. The performance characteristics of the drive system components and the variable-geometry diffuser system of the tunnel are documented and analyzed. Several potential methods for reducing the energy requirements of the facility are discussed.

Hasel, L. E.↗

Computational Modeling of Mars Retropropulsion Concepts in the Langley Unitary Plan Wind Tunnel

Future human Mars missions will require powered descent starting at supersonic conditions, something which has never been done before at Mars. Computational powered descent flowfield simulations have been completed at full-scale Mars conditions, but the available ground test data are not appropriate for calibrating computational uncertainties for aerodynamic interference on proposed Mars descent vehicles. A test will be conducted in the NASA Langley Unitary Plan Wind Tunnel to begin addressing powered descent aerodynamics risks for large-scale human Mars entry concepts and to identify gaps in computational predictive capabilities. This paper covers pre-test computational flowfield predictions of two different models derived from full-scale reference vehicles: a blunt low lift-to-drag vehicle and a more slender geometry. Calculations of the blunt model include variations in nozzle configuration: nozzle location, size, area ratio, and pointing direction. There exist some significant differences between solvers, but some general trends are observed from simulations of the blunt model. First, aerodynamic axial force from the heatshield decreases with increasing thrust due to expanding plume blockage. Second, nozzles that point along the model axis result in lower aerodynamic axial force compared to nozzles that have a radial thrust component. Finally, placing the nozzles further away from the model nose preserves more heatshield axial force with increasing thrust compared to nozzles that are closer to the nose. For the slender model, the axial force from the heatshield is similar to the non-blowing axial force regardless of thrust magnitude, due to the nozzle arrangement on the heatshield. Once the test is completed, direct comparisons between the computations and test data will be made to determine computational uncertainties in a wind tunnel environment, to identify gaps in predictive capabilities, and to inform planning for future ground and flight test programs for Mars powered descent vehicles.

Supersonic Retropropulsion↗

Status of Mars Retropropulsion Testing in the Langley Unitary Plan Wind Tunnel

Future Mars human landings will be enabled by a powered descent phase starting at supersonic conditions, something which has never been done before on a Mars mission. Significant aerosciences challenges exist due to jet interactions between the retrorocket engine plumes, freestream flow, and vehicle that will affect the aerodynamic behavior during powered descent. Historically, wind tunnel tests have been used to study the interactions with inert gas exhaust simulants in place of rocket engines. On the computational side, flowfield simulations have been completed at full-scale conditions, but the available ground and flight data are not appropriate for calibrating computational uncertainties for aerodynamic interference on proposed Mars descent vehicles, due to insufficient data, dissimilar vehicle geometries, and disparate operating conditions. A wind tunnel test has been designed to begin addressing powered descent aerodynamics risks for large-scale human Mars entry concepts and to identify gaps in computational predictive capabilities. The test will be conducted in the NASA Langley Unitary Plan Wind Tunnel and is designed with improvements in model design and data products over past tests. The test campaign will be run using sub-scale model geometries derived from NASA powered descent reference vehicles: a blunt low lift-to-drag vehicle and a more slender geometry that generates higher unpowered lift. Both models have been fabricated and are ready for testing. The blunt model is equipped with the flexibility to examine the effects of nozzle pointing direction, number, location, size, and area ratio. The main measurements are heatshield aerodynamic interference forces and moments with a custom flow-through balance, discrete and distributed heatshield pressure, and high-speed flowfield visualization. This paper covers the test objectives, facility, models and instrumentation, and planned test matrix.

Supersonic Retropropulsion↗

ARES I Aerodynamic Testing at the NASA Langley Unitary Plan Wind Tunnel

Small-scale force and moment and pressure models based on the outer mold lines of the Ares I design analysis cycle crew launch vehicle were tested in the NASA Langley Research Center Unitary Plan Wind Tunnel from May 2006 to September 2009. The test objectives were to establish supersonic ascent aerodynamic databases and to obtain force and moment, surface pressure, and longitudinal line-load distributions for comparison to computational predictions. Test data were obtained at low through high supersonic Mach numbers for ranges of the Reynolds number, angle of attack, and roll angle. This paper focuses on (1) the sensitivity of the supersonic aerodynamic characteristics to selected protuberances, outer mold line changes, and wind tunnel boundary layer transition techniques, (2) comparisons of experimental data to computational predictions, and (3) data reproducibility. The experimental data obtained in the Unitary Plan Wind Tunnel captured the effects of evolutionary changes to the Ares I crew launch vehicle, exhibited good agreement with predictions, and displayed satisfactory within-test and tunnel-to-tunnel data reproducibility.

Erickson, Gary E.↗

Pressure-Sensitive Paint and Video Model Deformation Systems at the NASA Langley Unitary Plan Wind Tunnel

Pressure-sensitive paint (PSP) and video model deformation (VMD) systems have been installed in the Unitary Plan Wind Tunnel at the NASA Langley Research Center to support the supersonic wind tunnel testing requirements of the High Speed Research (HSR) program. The PSP and VMD systems have been operational since early 1996 and provide the capabilities of measuring global surface static pressures and wing local twist angles and deflections (bending). These techniques have been successfully applied to several HSR wind tunnel models for wide ranges of the Mach number, Reynolds number, and angle of attack. A review of the UPWT PSP and VMD systems is provided, and representative results obtained on selected HSR models are shown. A promising technique to streamline the wind tunnel testing process, Modern Experimental Design, is also discussed in conjunction with recently-completed wing deformation measurements at UPWT.

Erickson, G. E.↗

Pressure-Sensitive Paint and Video Model Deformation Systems at the NASA Langley Unitary Plan Wind Tunnel

Pressure-sensitive paint (PSP) and video model deformation (VMD) systems have been installed in the Unitary Plan Wind Tunnel at the NASA Langley Research Center to support the supersonic wind tunnel testing requirements of the High Speed Research (HSR) program. The PSP and VMD systems have been operational since early 1996 and provide the capabilities of measuring global surface static pressures and wing local twist angles and deflections (bending). These techniques have been successfully applied to several HSR wind tunnel models for wide ranges of the Mach number, Reynolds number, and angle of attack. A review of the UPWT PSP and VMD systems is provided, and representative results obtained on selected HSR models are shown. A promising technique to streamline the wind tunnel testing process, Modern Experimental Design, is also discussed in conjunction with recently-completed wing deformation measurements at UPWT.

Erickson, G. E.↗

Evaluation of CFD Predictions of CobraMRV Control Surface Effectiveness at the NASA Langley Unitary Plan Wind Tunnel

The ability of CFD simulations to serve as a surrogate for wind tunnel testing at high supersonic speeds has been evaluated for a sub-scale model of the Co-Optimization Blunt-body Re-entry Analysis-Mid-lift-to-drag Rigid Vehicle (CobraMRV) human Mars entry vehicle concept. The vehicle was tested at the Unitary Plan Wind Tunnel (UPWT) at the NASA Langley Research Center under flow conditions and surface control configurations relevant to the entry stage of a flight mission. The CFD simulations were performed prior to gaining access to test results in order to assess how blind predictions obtained using best practices compare to experiments. Solutions of empty tunnel simulations were used as inflow boundary condition for the CobraMRV simulations in a truncated portion of the test section. Different solvers and turbulence models were used by separate teams to assess sensitivity to numerical methods, physics, and users. After release of the test results, the pre-test computations were compared to the experimental results, and additional analyses have been conducted to explain observed discrepancies. The amount of time and resources dedicated to each phase of the computational work was logged for comparison to that required for wind tunnel tests, and to inform planning of future CFD data base development projects.

ARMD↗

Flow Characterization of the NASA Langley Unitary Plan Wind Tunnel, Test Section 2: Computational Results

This is an abstract for an invited paper at the AIAA Aviation Conference, June 2021. The work described here is part of an effort of coordinated experiments in the Unitary Plan Wind Tunnel (UPWT) facility at the NASA Langley Research Center (LaRC) and matching CFD simulations. The primary goal of the work is to assess the productivity and true predictive accuracy of CFD, absent any guidance from experiment, in the high supersonic speed range as compared to experiments performed at the NASA LaRC’s UPWT facility. This report concerns CFD simulation of the primary flow-path in the empty wind tunnel, including the settling chamber, nozzle, test section, and some of the tunnel downstream of the test section. The Mach number in the test section ranges from M~2.4 to M~4.6, and the required area ratio variation is achieved by translation of a nozzle block which constricts the area of a loosely S-shaped throat. Flow past protuberances in the settling chamber and into this S-bend throat are predicted by CFD to generate streamwise vorticity that may, or may not, persist through the throat and into the test section as coherent vortices. Some flow conditions are notably unsteady at frequencies well below those of turbulence, due to unsteady separated flow ahead of the nozzle block. The bulk flow moves at velocities ranging from 'walking speed' in the settling chamber to M~4.6 in the test section. Heat transfer to the settling chamber walls and buoyancy are significant at high Mach number. Subtle variations in surface curvature in the nozzle generate Mach waves that propagate into the test section. CFD of the empty tunnel serves two purposes. Firstly, the full-tunnel simulations are used to provide upstream boundary conditions for CFD of vehicle aerodynamics which are generally performed in a domain confined to the wind tunnel test section; these companion studies are addressed in other papers. Secondly, it is a challenging test for CFD to resolve all of the empty tunnel flow phenomena relevant to flow in the test section. It requires a more complete definition of geometry than was originally anticipated. In addition, it requires good spatial and temporal accuracy, and turbulence modeling that performs well on specific phenomena such as corner flows. The boundary conditions and solution algorithms must perform well from incompressible to almost hypersonic speeds. The final state of the pre-test CFD was a product of an iterative self-improvement process. The initial simulations of the empty tunnel were deficient in many respects, but hints to those deficiencies were recognized in the solutions, and remedies were implemented. Possible further improvements will be studied in the post-test phase when comparisons with experimental data are possible. The CFD was performed by five separate collaborative teams using four different flow solvers: FUN3D, Overflow, Star-CCM+ and USM3D. The level of effort of these teams varied significantly, but each made important contributions to the goals of the work. A concerted effort to use uncertainty quantification methods (UQ) in CFD is also a goal of this work. To this end, variations in CFD results due to grid refinement, turbulence modeling, and boundary conditions have been characterized. Code-to-code variation is another means of assessing CFD uncertainty. All CFD solvers predict similarity among the primary flow features; these include the variation of Mach number due to changes in Reynolds number, and the bulk flow angularity due to tunnel-wall curvature. All CFD solvers also predict similar trends in secondary flows, such as the downwash in the side-wall boundary layers. Three of the high-spatial resolution simulations give similar predictions of a complex secondary flow phenomena, streamwise vortices generated in the S-bend throat that persist into the side-wall boundary layers of the test section. Two of the highest-resolution simulations, run with the same turbulence model in different CFD solvers, gave encouragingly similar predictions of a complex tertiary flow phenomenon, small transient "sprites" of upwash flows, resulting from vortices that presumably originate in the separated flow near the leading edge of the nozzle block. While the CFD was done in a "blind pre-test" mode, requests from the experimental team for CFD results pertaining to unsteadiness and total temperature variations in the test section resulted in CFD runs that included a cooled wall in settling chamber. This then led to a change in the standard practice for running the Overflow results, which would not have occurred without this "release" of this experimental information. CFD was also used to guide some measurements. The paper will focus on establishing the consensus among CFD results and understanding differences among those results. Initial findings from the efforts to characterize CFD uncertainty have been done and will be included in the paper.

Robert Edward Childs↗

Comparisons of boundary-layer transition measurement techniques in the Langley Unitary Plan wind tunnel

Four different boundary-layer transition detection techniques, namely liquid crystals, very thin hot films, IR photography, and an optical interferometer, were compared using the same flat plate model for the same tunnel conditions. The comparisons, conducted at NASA-Langley, involved not only their sensitivity to transition but also their ease of use. The thin films, as expected, gave excellent quantitative information and were used as the standard for evaluating the other techniques. Both the liquid crystals and IR photography were able to detect transition before the boundary-layer intermittency factor had reached 50 percent. The optical interferometer was unsuccessful. Conditions sampled included a range of Mach numbers from 1.5 to 2.5 and unit Reynolds numbers from 1.0 to 4.0 million/foot.

Hall, R. M.↗

Operational flow visualization techniques in the Langley Unitary Plan Wind Tunnel

The unitary plan wind tunnel (UPWT) uses in daily operation are shown. New ideas for improving the quality of established flow visualization methods are developed and programs on promising new flow visualization techniques are pursued. The unitary plan wind tunnel is a supersonic facility, referred to as a production facility, although the majority of tests are inhouse basic research investigations. The facility has two 4 ft. by 4 ft. test sections which span a Mach range from 1.5 to 4.6. The cost of operation is about $10 per minute. Problems are the time required for a flow visualization test setup and investigation costs and the ability to obtain consistently repeatable results. Examples of sublimation, vapor screen, oil flow, minitufts, schlieren, and shadowgraphs taken in UPWT are presented. All tests in UPWT employ one or more of the flow visualization techniques.

Corlett, W. A.↗

Schlieren Movies of the 8-Inch Diameter Rigid Parachute Model of the Cook Research Laboratory Taken During the Fourth Phase of Testing in the Langley Unitary Plan Wind Tunnel

Canopy Model IV was tested in four different configuration series. Shroud lines were used in the first three series of tests; none were used in the fourth series. Other variables were Mach number (1.77, 2.17, 2.76), dynamic pressure (290, 250, 155 lb per sq ft), camera speed, and attitude.

[Tunnel] Unitary Plan Wind Tunnel↗

Analysis of Dynamic Data from Supersonic Retropropulsion Experiments in NASA Langley's Unitary Plan Wind Tunnel

Recent experimental supersonic retropropulsion tests were conducted at the NASA Langley Research Center Unitary Plan Wind Tunnel Test Section 2 for a range of Mach numbers from 2.4 to 4.6. A 5-inch 70-degree sphere-cone forebody model with a 10-inch cylindrical aftbody experimental model was used which is capable of multiple retrorocket configurations. These configurations include a single central nozzle on the center point of the forebody, three nozzles at the forebody half-radius, and a combination of the first two configurations with no jets being plugged. A series of measurements were achieved through various instrumentation including forebody and aftbody pressure, internal pressures and temperatures, and high speed Schlieren visualization. Specifically, several high speed pressure transducers on the forebody and in the plenum were implemented to look at unsteady flow effects. The following work focuses on analyzing frequency traits due to the unsteady flow for a range of thrust coefficients for single, tri, and quad-nozzle test cases at freestream Mach 4.6 and angle of attack ranging from -8 degrees to +20 degrees. This analysis uses Matlab s fast Fourier transform, Welch's method (modified average of a periodogram), to create a power spectral density and analyze any high speed pressure transducer frequency traits due to the unsteady flow.

Codoni, Joshua R.↗

Testing of the Trim Tab Parametric Model in NASA Langley's Unitary Plan Wind Tunnel

In support of NASA's Entry, Descent, and Landing technology development efforts, testing of Langley's Trim Tab Parametric Models was conducted in Test Section 2 of NASA Langley's Unitary Plan Wind Tunnel. The objectives of these tests were to generate quantitative aerodynamic data and qualitative surface pressure data for experimental and computational validation and aerodynamic database development. Six component force-and-moment data were measured on 38 unique, blunt body trim tab configurations at Mach numbers of 2.5, 3.5, and 4.5, angles of attack from -4deg to +20deg, and angles of sideslip from 0deg to +8deg. Configuration parameters investigated in this study were forebody shape, tab area, tab cant angle, and tab aspect ratio. Pressure Sensitive Paint was used to provide qualitative surface pressure mapping for a subset of these flow and configuration variables. Over the range of parameters tested, the effects of varying tab area and tab cant angle were found to be much more significant than varying tab aspect ratio relative to key aerodynamic performance requirements. Qualitative surface pressure data supported the integrated aerodynamic data and provided information to aid in future analyses of localized phenomena for trim tab configurations.

Murphy, Kelly J.↗