Evaluation of CFD as a Surrogate for Wind-Tunnel Testing: Experimental Uncertainty Quantification for the UPWT Flow Survey Test
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Erin Hubbard↗
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UPWT CSM Vortex Characterization
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Matthew Alexander Reed↗
UPWT Characterization Plan
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Matthew Alexander Reed↗
Laser Incident in the NASA Unitary Plan Wind Tunnel
A viewgraph presentation describing the laser incident in the NASA Unitary Plan Wind Tunnel (UPWT) is shown. The topics include: 1) Unitary Plan Wind Tunnel (UPWT); 2) UPWT 11' x 11' Transonic Wind Tunnel; 3) UPWT 9' x 7' Supersonic Wind Tunnel; 4) 3D Particle Image Velocimetry (PIV); 5) PIV System in 11' x 11' Transonic Test Section; 6) PIV installation in 11' x 11' TWT; 7) 3% Space Shuttle Ascent Configuration Test in UPWT 9' x 7' Test Section; 8) PIV installation in 9' x 7' SWT; 9) PIV Laser System in 9' x 7' SWT; 10) PIV Laser System Access Window; 11) Cooling Water Leak at Rear of Power Supply; 12) PIV Laser Safety Interlock System; 13) Safety Interlock Cable; 14) Q-Switch located on top of 9' x 7' Test Section; 15) Investigation Findings and Recommendations; and 16) PIV Results for 3% Space Shuttle Model in UPWT 9' x 7'.
George, Michael W.↗
2012 Ground Testing Highlights
As part of the Fundamental Aeronautics Program and a collaborative effort with Boeing, and Lockheed Martin this past year a series of sonic boom test were completed in the NASA Ames Unitary Plan Wind Tunnel (UPWT). One of the goals was to develop new test techniques and hardware for measuring sonic boom signatures in the transonic and supersonic regimes. Data for various model designs and configurations were collected and will be used to validate CFD predictions of sonic boom signatures. Reactivation of the NASA Ames Mitsubishi compressor system was completed this past year. The compressor is intended to replace and augment the existing UPWT Clark Compressor as the primary Make Up Air (MUA) source. The MUA system provides air and vacuum pumping capability to the Ames UPWT. It will improve productivity and reliability of the UPWT as a vital testing and research facility for the U.S. aerospace industry and NASA. Funding for this task was provided from the American Recovery Investment Act (ARRA). Installation and validation of a Noncontact Stress Monitoring System (NSMS) for the 3-stage compressor was completed at the 11-foot Transonic Wind Tunnel. The system, originally developed at AEDC, consists of 36 pairs of LED light sources with optic beam send and receive probes along a 1-per rev signal. The new system allows for continuous monitoring and recording of compressor blade bending and torsion stress during normal test operations. A very unusual test was completed in the 11 FT TWT to acquire aerodynamic and flow field data for the Crew Exploration Vehicle (CEV) Parachute Assembly System (CPAS) to validate CFD methods and tools. Surface pressure distribution measurements and velocity measurements in the wake of the command module back to the drogues parachute location were acquired. Testing methods included Particle Image Velocimetry (PIV), Pressure Sensitive Paint (PSP), Schlieren Infrared Imaging (IR) and boundary layer survey and skin friction.
Buchholz, Steven J.↗
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.↗
Experimental Investigation of a Point Design Optimized Arrow Wing HSCT Configuration
The M2.4-7A Arrow Wing HSCT configuration was optimized for straight and level cruise at a Mach number of 2.4 and a lift coefficient of 0.10. A quasi-Newton optimization scheme maximized the lift-to-drag ratio (by minimizing drag-to-lift) using Euler solutions from FL067 to estimate the lift and drag forces. A 1.675% wind-tunnel model of the Opt5 HSCT configuration was built to validate the design methodology. Experimental data gathered at the NASA Langley Unitary Plan Wind Tunnel (UPWT) section #2 facility verified CFL3D Euler and Navier-Stokes predictions of the Opt5 performance at the design point. In turn, CFL3D confirmed the improvement in the lift-to-drag ratio obtained during the optimization, thus validating the design procedure. A data base at off-design conditions was obtained during three wind-tunnel tests. The entry into NASA Langley UPWT section #2 obtained data at a free stream Mach number, M(sub infinity), of 2.55 as well as the design Mach number, M(sub infinity)=2.4. Data from a Mach number range of 1.8 to 2.4 was taken at UPWT section #1. Transonic and low supersonic Mach numbers, M(sub infinity)=0.6 to 1.2, was gathered at the NASA Langley 16 ft. Transonic Wind Tunnel (TWT). In addition to good agreement between CFD and experimental data, highlights from the wind-tunnel tests include a trip dot study suggesting a linear relationship between trip dot drag and Mach number, an aeroelastic study that measured the outboard wing deflection and twist, and a flap scheduling study that identifies the possibility of only one leading-edge and trailing-edge flap setting for transonic cruise and another for low supersonic acceleration.
Narducci, Robert P.↗
Aerothermal Protuberance Heating Design and Test Configurations for Ascent Vehicle Design
A series of tests were conducted to evaluate protuberance heating for the purposes of vehicle design and modification. These tests represent a state of the art approach to both testing and instrumentation for defining aerothermal protuberance effects on the protuberance and surrounding areas. The testing was performed with a number of wind tunnel entries beginning with the proof of concept "pathfinder" test in the Test Section 1 (TS1) tunnel in the Langley Unitary Plan Wind Tunnel (UPWT). The TS1 section (see Figures 1a and 1b) is a lower Mach number tunnel and the Test Section 2 (TS2) has overlapping and higher Mach number capability as showin in Figure 1c. The pathfinder concept was proven and testing proceeded for a series of protuberance tests using an existing splitter aluminum protuberance mounting plate, Macor protuberances, thin film gages, total temperature and pressure gages, Kulite pressure transducers, Infra-Red camera imaging, LASER velocimetry evaluations and the UPWT data collection system. A boundary layer rake was used to identify the boundary layer profile at the protuberance locations for testing and helped protuberance design. This paper discusses the techniques and instrumentation used during the protuberance heating tests performed in the UPWT in TS1 and TS2. Runs of the protuberances were made Mach numbers of 1.5, 2.16, 2.65, and 3.51. The data set generated from this testing is for ascent protuberance effects and is termed Protuberance Heating Ascent Data (PHAD) and this testing may be termed PHAD-1 to distinguish it from future testing of this type.
Martin, Charles E.↗
Invited: uPSP Launch Vehicle Demonstration Test at NASA Ames Research Center
The Unsteady Pressure-Sensitive Paint (uPSP) Development Team outof NASA Ames Research Center (ARC) has spent the past five yearsimproving the systems and processes to advance the uPSP technology for production-level wind tunnel testing. Already considered turnkey for small-scale and research applications, development in acquisition, calibration, data transfer, and data processing were needed to be useful to customers testing at NASA wind tunnels. This development focused at ARC at the Unitary Plan Wind Tunnel (UPWT) 11-by 11-ft Transonic Wind Tunnel due to the large optical access of the test section and the NASA Advanced Supercomputer(NAS), also located at ARC. A Launch Vehicle Demonstration Test (LVDT) at the UPWT represents a milestone of this initial phase of development where several new improvements were demonstrated in a production wind tunnel environment for the first time. LVDT was conducted in April 2024 and used a 4% forebody Space Launch System (SLS) Block 1B model as the test article. Both a crew and cargo configuration were tested, with varying Mach numbers, pressures, model positions, and camera magnifications. This paper summarizes the details of the test and is part of a collection with four additional papers that provide greater detail on: high-speed lifetime methodology, spectral proper orthogonal decomposition analysis, quality of high-resolution data compared to Corcos model, and data quality, calibration, and uncertainty.
SLS↗
Aerodynamic heating to corrugation stiffened structures in thick turbulent boundary layers
The results of an experimental program to evaluate heat transfer and pressure distributions on corrugation roughened flat plates in thick turbulent boundary layers are presented. The experimental program consisted of tests in the tunnel wall boundary layers of the Langley Unitary Plan Wind Tunnel (UPWT) and Continuous Flow Hypersonic Tunnel (CFHT) at freestream Mach numbers of 2.5, 3.5, 4.5, and 10.3. Tests in the UPWT were conducted at a freestream Reynolds number/m of 10,800,000 and in the CFHT, at Reynolds numbers/m of 1,300,000 to 5,800,000. The test configurations consisted of 50.8 x 50.8 cm panels with corrugated beads of two different peak amplitudes, 0.61 and 0.29 cm. The angle of the corrugated beads relative to the flow direction was varied between 0 (aligned) and 90 deg (normal). The measured peak and average heat transfer are analyzed and correlated in terms of the bulk boundary layer, internal boundary layer, and geometric parameters.-
Brandon, H. J.↗
Pressure distributions on a 0.04-scale model of the Space Shuttle Orbiter's forward fuselage in the Langley unitary plan wind tunnel
Pressure distribution tests on a 0.04-scale model of the forward fuselage of the Space Shuttle Orbiter are presented without analysis. The tests were completed in the Langley Unitary Plan Wind Tunnel (UPWT). The UPWT has two different test sections operating in the continuous mode. Each test section has its own Mach number range. The model was tested at angles of attack from -2.5 deg to 30 deg and angles of sideslip from -5 deg to 5 deg in both test sections. The test Reynolds number was 6.6 x 10 to the 6th power per meter. The tests were conducted in support of the development of the Shuttle Entry Air Data System (SEADS). In addition to modeling the 20 SEADS pressure orifices, the wind-tunnel model was also instrumented with orifices to match Development Flight Instrumentation (DFI) port locations currently existing on the Space Shuttle Orbiter Columbia (OV-102). This DFI simulation has provided a means for comparisons between reentry flight pressure data and wind-tunnel data.
Bradley, P. F.↗
Pressure distributions obtained on a 0.10-scale model of the Space Shuttle Orbiter's forebody in the Ames Unitary Plan Wind Tunnel
Pressure distribution test data obtained on a 0.10-scale model of the forward fuselage of the Space Shuttle Orbiter are presented without analysis. The tests were completed in the Ames Unitary Wind Tunnel (UPWT). The UPWT tests were conducted in two different test sections operating in the continuous mode, the 8 x 7 feet and 9 x 7 feet test sections. Each test section has its own Mach number range, 1.6 to 2.5 and 2.5 to 3.5 for the 9 x 7 feet and 8 x 7 feet test section, respectively. The test Reynolds number ranged from 1.6 to 2.5 x 10 to the 6th power ft and 0.6 to 2.0 x 10 to the 6th power ft, respectively. The tests were conducted in support of the development of the Shuttle Entry Air Data System (SEADS). In addition to modeling the 20 SEADS orifices, the wind-tunnel model was also instrumented with orifices to match Development Flight Instrumentation (DFI) port locations that existed on the Space Shuttle Columbia (OV-102) during the Orbiter Flight test program. This DFI simulation has provided a means for comparisons between reentry flight pressure data and wind-tunnel and computational data.
Siemers, P. M., III↗
NCV Flow Diagnostic Test Results
There were two objectives for this test. First, was to assess the reasons why there is approximately 1.5 drag counts (cts) discrepancy between measured and computed drag improvement of the Non-linear Cruise Validation (NCV) over the Technology Concept Airplane (TCA) wing body (WB) configurations. The Navier-Stokes (N-S) pre-test predictions from Boeing Commercial Airplane Group (BCAG) show 4.5 drag cts of improvement for NCV over TCA at a lift coefficient (CL) of 0. I at Mach 2.4. The pre-test predictions from Boeing Phantom Works - Long Beach, BPW-LB, show 3.75 drag cts of improvement. BCAG used OVERFLOW and BPW-LB used CFL3D. The first test entry to validate the improvement was held at the NASA Langley Research Center (LARC) UPV;T, test number 1687. The experimental results showed that the drag improvement was only 2.6 cts, not accounting for laminar run and trip drag. This is approximately 1.5 cts less than predicted computationally. In addition to the low Reynolds Number (RN) test, there was a high RN test in the Boeing Supersonic Wind Tunnel (BSWT) of NCV and TCA. BSV@T test 647 showed that the drag improvement of NCV over TCA was also 2.6 cts, but this did account for laminar run and trip drag. Every effort needed to be done to assess if the improvement measured in LaRC UPWT and BSWT was correct. The second objective, once the first objective was met, was to assess the performance increment of NCV over TCA accounting for the associated laminar run and trip drag corrections in LaRC UPWT. We know that the configurations tested have laminar flow on portions of the wing and have trip drag due to the mechanisms used to force the flow to go from laminar to turbulent aft of the transition location.
Cappuccio, Mina↗
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.↗
Overview of Selected Measurement Techniques for Aerodynamics Testing in the NASA Langley Unitary Plan Wind Tunnel
An overview is given of selected measurement techniques used in the NASA Langley Research Center (LaRC) Unitary Plan Wind Tunnel (UPWT) to determine the aerodynamic characteristics of aerospace vehicles operating at supersonic speeds. A broad definition of a measurement technique is adopted in this paper and is any qualitative or quantitative experimental approach that provides information leading to the improved understanding of the supersonic aerodynamic characteristics. On surface and off-surface measurement techniques used to obtain discrete (point) and global (field) measurements and planar and global flow visualizations are described, and examples of all methods are included. The discussion is limited to recent experiences in the UPWT and is. therefore, not an exhaustive review of existing experimental techniques. The diversity and high quality of the measurement techniques and the resultant data illustrate the capabilities of a around-based experimental facility and the key role that it plays in the advancement of our understanding, prediction, and control of supersonic aerodynamics.
Erickson, Gary E.↗
Modernization and Activation of the NASA Ames 11- by 11-Foot Transonic Wind Tunnel
The Unitary Plan Wind Tunnel (UPWT) was modernized to improve performance, capability, productivity, and reliability. Automation systems were installed in all three UPWT tunnel legs and the Auxiliaries facility. Major improvements were made to the four control rooms, model support systems, main drive motors, and main drive speed control. Pressure vessel repairs and refurbishment to the electrical distribution system were also completed. Significant changes were made to improve test section flow quality in the 11-by 11-Foot Transonic leg. After the completion of the construction phase of the project, acceptance and checkout testing was performed to demonstrate the capabilities of the modernized facility. A pneumatic test of the tunnel circuit was performed to verify the structural integrity of the pressure vessel before wind-on operations. Test section turbulence, flow angularity, and acoustic parameters were measured throughout the tunnel envelope to determine the effects of the tunnel flow quality improvements. The new control system processes were thoroughly checked during wind-off and wind-on operations. Manual subsystem modes and automated supervisory modes of tunnel operation were validated. The aerodynamic and structural performance of both the new composite compressor rotor blades and the old aluminum rotor blades was measured. The entire subsonic and supersonic envelope of the 11-by 11-Foot Transonic leg was defined up to the maximum total pressure.
Kmak, Frank J.↗
Cone-Probe Rake Design and Calibration for Supersonic Wind Tunnel Models
A series of experimental investigations were conducted at the NASA Langley Unitary Plan Wind Tunnel (UPWT) to calibrate cone-probe rakes designed to measure the flow field on 1-2% scale, high-speed wind tunnel models from Mach 2.15 to 2.4. The rakes were developed from a previous design that exhibited unfavorable measurement characteristics caused by a high probe spatial density and flow blockage from the rake body. Calibration parameters included Mach number, total pressure recovery, and flow angularity. Reference conditions were determined from a localized UPWT test section flow survey using a 10deg supersonic wedge probe. Test section Mach number and total pressure were determined using a novel iterative technique that accounted for boundary layer effects on the wedge surface. Cone-probe measurements were correlated to the surveyed flow conditions using analytical functions and recursive algorithms that resolved Mach number, pressure recovery, and flow angle to within +/-0.01, +/-1% and +/-0.1deg , respectively, for angles of attack and sideslip between +/-8deg. Uncertainty estimates indicated the overall cone-probe calibration accuracy was strongly influenced by the propagation of measurement error into the calculated results.
Won, Mark J.↗