Full scale turbofan duct burner test program Final report, 29 Jun. 1965 - 30 Jun. 1967
Performance, and structural durability of full scale turbofan duct burner at simulated supersonic transport flight
Clapp, C. J.↗
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Integrated Resilient Aircraft Control Project Full Scale Flight Validation
Objective: Provide validation of adaptive control law concepts through full scale flight evaluation. Technical Approach: a) Engage failure mode - destabilizing or frozen surface. b) Perform formation flight and air-to-air tracking tasks. Evaluate adaptive algorithm: a) Stability metrics. b) Model following metrics. Full scale flight testing provides an ability to validate different adaptive flight control approaches. Full scale flight testing adds credence to NASA's research efforts. A sustained research effort is required to remove the road blocks and provide adaptive control as a viable design solution for increased aircraft resilience.
Bosworth, John T.↗
TPSAS-NF1676L-32920-DND
In June 2019, a full-scale crash test of a Fokker F28 Fellowship aircraft will be conducted at NASA Langley Research Center?s Landing and Impact Research (LandIR) Facility. The F28 is a high-performance twin-turbo fan narrow-body aircraft with seating in a 3+2 configuration. The MK4000 variant, used in this test, is capable of carrying up to 85 passengers on medium range routes. The F28 was first type certified by the Federal Aviation Administration (FAA) in 1969 and now the majority of the F28 fleet has retired from service in the United States. In 2016, the FAA and NASA Langley Research Center (LaRC) signed an interagency agreement for conducting a research program to obtain test data that will support the development of airframe level crash requirements for transport category airplanes [1]. The objectives of the full-scale crash test can be divided into six categories: (1) To compare and contrast responses in identical aircraft undergoing vertical only to combined vertical and horizontal loading conditions, (2) To examine the effects of horizontal loading on aircraft structure during a crash event, (3) To generate data for the use in calibration of computer modelling efforts, (4) To generate data from onboard Anthropomorphic Test Devices (ATDs) for the evaluation of injury, (5) To obtain data from experimental seats, and (6) To obtain data from new and novel ATD designs including Warrior Injury Assessment MANikin (WIAMan) [2], Test device for Human Occupant Response (THOR), and other newly developed child ATDs. The focus of this presentation will be to document finite element model development of the full-scale F28 aircraft and to present preliminary test-analysis predictions. NASA obtained the full-scale F28 aircraft, plus three fuselage sections and two sets of wings with funding through the NASA Aviation Safety Program in 1998. In addition to the hardware, NASA purchased a full NASTRAN model of the airframe that had been developed by the Dutch manufacturer, Fokker. Beginning in 2016, the NASTRAN model was converted to LS-DYNA? [4, 5] format and modified by combining parts, adding missing parts of internal structure, and including ballast for loading weights, etc. It contains: 89,223 nodes; 24,065 beam elements; 55,404 shell elements; 29,044 solid elements; 740 parts; 80 material definitions; and, 46 Constrained Nodal Rigid Bodies (CNRBs). The aircraft model will be executed in LSDYNA to simulate the test article impact onto a 2-ft.-high bed of soil under combined velocity conditions of 70-ft/s forward and 30-ft/s vertical velocity. Pre-test simulation predictions will be generated and correlated with test data.
Karen E Jackson↗
Unique Tuft Test Facility Dramatically Reduces Brush Seal Development Costs
Brush seals have been incorporated in the latest turbine engines to reduce leakage and improve efficiency. However, the life of these seals is limited by wear. Studies have shown that optimal sealing characteristics for a brush seal occur before the interference fit between the brush and shaft is excessively worn. Research to develop improved tribopairs (brush and coating) with reduced wear and lower friction has been hindered by the lack of an accurate, low-cost, efficient test methodology. Estimated costs for evaluating a new material combination in an engine company seal test program are on the order of $100,000. To address this need, the NASA Lewis Research Center designed, built, and validated a unique, innovative brush seal tuft tester that slides a single tuft of brush seal wire against a rotating shaft under controlled loads, speeds, and temperatures comparable to those in turbine engines. As an initial screening tool, the brush seal tuft tester can tribologicaly evaluate candidate seal materials for 1/10th the cost of full-scale seal tests. Previous to the development of the brush seal tuft tester facility, most relevant tribological data had been obtained from full-scale seal tests conducted primarily to determine seal leakage characteristics. However, from a tribological point of view, these tests included the confounding effects of varying contact pressures, bristle flaring, high-temperature oxidation, and varying bristle contact angles. These confounding effects are overcome in tuft testing. The interface contact pressures can be either constant or varying depending on the tuft mounting device, and bristle wear can be measured optically with inscribed witness marks. In a recent cooperative program with a U.S. turbine engine manufacturer, five metallic wire candidates were tested against a plasma-sprayed Nichrome-bonded chrome carbide. The wire materials used during this collaboration were either nickel-chrome- or cobaltchrome-based superalloys. These tests corroborated full-scale seal test results and provided insight into previously untested combinations. As the cycle temperature for improved efficiency turbine engines increases, new brush seal materials combinations must be considered. Future brush seal tuft testing will include both metallic and ceramic bristles versus commercial and NASA-developed shaft coatings. The ultimate goal of this work is to expand the current data base so that seal designers can tailor brush seal materials to specific applications.
Fellenstein, James A.↗
Evaluation of dispersion strengthened nickel-base alloy heat shields for space shuttle application
The design, fabrication, and testing of a full-size, full-scale TD Ni-20Cr heat shield test array in simulated mission environments is described along with the design and fabrication of two additional full-size, full-scale test arrays to be tested in flowing gas test facilities at the NASA Langley Research Center. Cost and reusability evaluations of TD Ni-20Cr heat shield systems are presented, and weight estimates of a TD Ni-20Cr heat shield system for use on a shuttle orbiter vehicle are made. Safe-line expectancy of a TD Ni-20Cr heat shield system is assessed. Non-destructive test techniques are evaluated to determine their effectiveness in quality assurance checks of TD Ni-20Cr components such as heat shields, heat shield supports, close-out panels, formed cover strips, and edge seals. Results of tests on a braze reinforced full-scale, subsize panel are included. Results show only minor structural degradation in the main TD Ni-20Cr heat shields of the test array during simulated mission test cycles.
Johnson, R., Jr.↗
Mars Ascent Vehicle Hybrid Propulsion Development
Hybrid propulsion is being investigated as a propulsion method for a possible Mars Ascent Vehicle (MAV) application. MAV is part of a proposed larger Mars Sample Return (MSR) campaign plan to bring samples from Mars to earth for examination. The Mars Ascent Vehicle would launch Mars surface samples found and packaged by the Mars 2020 mission to orbit around Mars. This version of hybrid propulsion is based on a wax based solid fuel, called SP7A, and a Mixed Oxides of Nitrogen oxidizer, MON-25. SP7 is a new fuel formulation developed by Space Propulsion Group and was modified for this application to be resistant to Mars temperature extremes and modified again to lower the regression rate to become SP7A. MON-25 was chosen for its low freezing temperature. Due to cost constraints, MON-3 was the oxidizer used during testing through 2018. In 2019, full scale hybrid testing with MON-25 commenced in Mojave, CA by Whittinghill Aerospace. One flight motor will be subjected to thermal cycling in a vacuum and later fired in a vacuum to demonstrate the proposed Liquid Injection Thrust Vector Control system performance at White Sands Test Facility (WSTF). In addition, there will be MON-25 characterization work done at Purdue University and WSTF. Additional testing of subscale and full scale motors will be conducted with MON-3 with fuel grain stress, fuel grain support and case design test objectives by Space Propulsion Group Inc. of Butte, MT. This paper documents some of the testing, issues and accomplishments with the MAV hybrid propulsion option that is being considered (along with a two-stage solid propulsion option).
Story, G. T.↗
Tests of a full-scale annular ram-induction combustor for a Mach 3 cruise turbojet engine
Full-scale annular ram-induction combustor tests for Mach 3 cruise turbojet engine
Perkins, P. J.↗
Jet Engine Bird Ingestion Simulations: Comparison of Rotating to Non-Rotating Fan Blades
Bird strike events in commercial airliners are a fairly common occurrence. According to data collected by the US Department of Agriculture, over 80,000 bird strikes were reported in the period 1990-2007 in the US alone [1]. As a result, bird ingestion is an important factor in aero engine design and FAA certification. When it comes to bird impacts on engine fan blades, the FAA requires full-scale bird ingestion tests on an engine running at full speed to pass certification requirements. These rotating tests are complex and very expensive. To reduce development costs associated with new materials for fan blades, it is desirable to develop more cost effective testing procedures than full-scale rotating engine tests for material evaluation. An impact test on a non-rotating single blade that captures most of the salient physics of the rotating test would go a long way towards enabling large numbers of evaluative material screening tests. NASA Glenn Research Center has been working to identify a static blade test procedure that would be effective at reproducing similar results as seen in rotating tests. The current effort compares analytical simulations of a bird strike on various nonrotating blades to a bird strike simulation on a rotating blade as a baseline case. Several different concepts for simulating the rotating loads on a non-rotating blade were analyzed with little success in duplicating the deformation results seen in the rotating case. The rotating blade behaves as if it were stiffer than the non-rotating blade resulting in less plastic deformation from a given bird impact. The key factor limiting the success of the non-rotating blade simulations is thought to be the effect of gyroscopics. Prior to this effort, it was anticipated the difficulty would be in matching the pre-stress in the blade due to centrifugal forces Additional work is needed to verify this assertion, and to determine if a static test procedure can simulate the gyroscopic effects in a suitable manner. This paper describes the various non-rotating concepts analyzed, and demonstrates the effect believed to be gyroscopic in nature on the results.
Howard, Samuel A.↗
Jet Engine Bird Ingestion Simulations: Comparison of Rotating to Non-Rotating Fan Blades
Bird strike events in commercial airliners are a fairly common occurrence. According to data collected by the US Department of Agriculture, over 80,000 bird strikes were reported in the period 1990 to 2007 in the US alone (Ref. 1). As a result, bird ingestion is an important factor in aero engine design and FAA certification. When it comes to bird impacts on engine fan blades, the FAA requires full-scale bird ingestion tests on an engine running at full speed to pass certification requirements. These rotating tests are complex and very expensive. To reduce development costs associated with new materials for fan blades, it is desirable to develop more cost effective testing procedures than full-scale rotating engine tests for material evaluation. An impact test on a nonrotating single blade that captures most of the salient physics of the rotating test would go a long way towards enabling large numbers of evaluative material screening tests. NASA Glenn Research Center has been working to identify a static blade test procedure that would be effective at reproducing similar results as seen in rotating tests. The current effort compares analytical simulations of a bird strike on various non-rotating blades to a bird strike simulation on a rotating blade as a baseline case. Several different concepts for simulating the rotating loads on a non-rotating blade were analyzed with little success in duplicating the deformation results seen in the rotating case. The rotating blade behaves as if it were stiffer than the non-rotating blade resulting in less plastic deformation from a given bird impact. The key factor limiting the success of the non-rotating blade simulations is thought to be the effect of gyroscopics. Prior to this effort, it was anticipated the difficulty would be in matching the prestress in the blade due to centrifugal forces Additional work is needed to verify this assertion, and to determine if a static test procedure can simulate the gyroscopic effects in a suitable manner. This paper describes the various non-rotating concepts analyzed, and demonstrates the effect believed to be gyroscopic in nature on the results
Howard, Samuel A.↗
Use of Dynamically Scaled Models for Studies of the High-Angle-of-Attack Behavior of Airplanes
Dynamically scaled, free-flying models are used by the National Aeronautics and Space Administration (NASA) to study the stalling and spinning characteristics of civil and military airplane configurations. Such tests have been conducted for many different designs, and it has been possible to correlate the results predicted by the model tests with flight test results obtained in the investigations. The present paper describes four of the dynamic model testing techniques used at the NASA Langley Research Center, including the scaling laws used in the construction of models and in the interpretation of results. Predictions of stall/spin behavior based on model results have generally been very accurate, and the model tests are regarded as an invaluable precursor to full-scale flight tests. However, aerodynamic scale effects between some models and full-scale airplanes due to differences in test values of Reynolds number have resulted in erroneous predictions for a few configurations. A discussion of these effects is provided, together with the approach used to modify the model so that its behavior more closely matches that of the airplane. Finally, two typical applications of the techniques to the X-29A research airplane and several general aviation research airplanes are presented to illustrate the type of information provided by the tests.
Joseph R Chambers↗
Use of dynamically scaled models for studies of the high-angle-of-attack behavior of airplanes
Dynamically scaled, free-flying models are used by the National Aeronautics and Space Administration (NASA) to study the stalling and spinning characteristics of civil and military airplane configurations. Such tests have been conducted for many different designs, and it has been possible to correlate the results predicted by the model tests with flight test results obtained in the investigations. The present paper describes four of the dynamic model testing techniques used at the NASA Langley Research Center, including the scaling laws used in the construction of models and in the interpretation of results. Predictions of stall/spin behavior based on model results have generally been very accurate, and the model tests are regarded as an invaluable precursor to full-scale flight tests. However, aerodynamic scale effects between some models and full-scale airplanes due to differences in test values of Reynolds number have resulted in erroneous predictions for a few configurations. A discussion of these effects is provided, together with the approach used to modify the model so that its behavior more closely matches that of the airplane. Finally, two typical applications of the techniques to the X-29A research airplane and several general aviation research airplanes are presented to illustrate the type of information provided by the tests.
Joseph R Chambers↗
Hanford Waste Treatment Plant Effluent Management Facility Stack Effluent Monitoring: Sampling Probe Location Qualification Evaluation
The Hanford Tank Waste Treatment and Immobilization Plant Effluent Management Facility (EMF) stack monitor location was qualified using a combination of scale model stacks to mitigate the risk of identifying that the sampling location does not meet the qualification criteria on the full-scale stack. The LV-S1 scale model stack was used as a baseline, augmented by the LB-S1 and LV-S2 scale model stacks to address the Direct Feed Low Activity Waste Effluent Management Facility Vessel Vent Process (DVP) injection into the main Active Confinement Ventilation (ACV) system duct. As required by the American National Standards Institute/Health Physics Society (ANSI/HPS) N13.1-1999 standard, the scale model and its sampling locations were geometrically similar to the actual stack, and the Reynolds numbers for both the actual and model stacks were >10,000. An additional criterion is that the product of the hydraulic diameter and mean velocity (DV) of the full-scale stack must be between 1/6 DV and 6 DV of the scale model stack tests. The LV-S1, LB-S1, and LV-S2 scale model stack tests have met the criteria of the ANSI/HPS N13.1-1999 standard to demonstrate the stack sampling locations are well mixed. Verification tests of the EMF stack were performed at normal operating conditions. The minimum 1/6 DV value and the maximum 6 DV value from the scale model testing determine the range of stack flow rates for which the full-scale stack may be operated while remaining in compliance with the stack verification criterion. A practical range for the full-scale stack qualification uses the average DV through 6 DV from the scale model tests to compute the corresponding flow rates. Table S1 lists the operating flow rate along with the average and maximum qualified stack flow rate based on the LV-S1 scale model DV values. The operating flow is below the maximum qualified stack flow, which means that the scale model test results are acceptable for stack qualification. The remaining criteria for the stack verification to be considered valid involve the flow angle and velocity uniformity results. First, the flow angle at the full-scale stack must be ≤20°. Second, the velocity uniformity at the full-scale stack must be ≤20% coefficient of variance (COV). Finally, the velocity uniformity results for the actual and scale model stack tests must agree within 5% COV. These criteria were met through the full-scale stack test at the EMF. Flow angle results were <5°; all flow angle results were within the ≤20° criterion. The velocity uniformity results for each test condition ranged between 2.2% COV and 4.3% COV, all of which were within the range of the target % COV values from the scale model tests on the LV-S1, LB-S1, and LV S2 scale models. Based on these stack verification test results, the EMF filtered exhaust stack sampling location meets the qualification criteria provided in the ANSI/HPS N13.1-1999 standard for all planned fan operating configurations. This includes each combination of ACV fans with DVP exhausters. Further changes to the system configuration or operating conditions that are outside the qualified flow rates described in this report may require additional tests or analyses to determine compliance with the standard.
12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
Full-scale wind-tunnel tests of a small unpowered jet aircraft with a T-tail
The aerodynamic characteristics of a full scale executive type jet transport aircraft with a T-tail were investigated in a 40 x 80 ft (12.2 by 24.4 meter) wind tunnel (subsonic). Static, longitudinal, and lateral stability, and control characteristics were determined at angles of attack from -2 deg to +42 deg. The aircraft wing had 13 deg of sweep and an aspect ratio of 5.02. The aircraft was tested power off with various wing leading- and trailing-edge high lift devices. The basic configuration was tested with and without such components as engine nacelles, wing tip tanks, and empannage. Hinge-moment data were obtained and downwash angles in the horizontal-tail plane location were calculated. The data were obtained at Reynolds numbers of 4.1 million and 8.7 million based on mean aerodynamic chord. The model had static longitudinal stability through initial stall. Severe tail buffet occurred near the angle of attack for maximum lift. Above initial stall the aircraft had pronounced pitch-up, characteristic of T-tail configurations. A stable trim point was possible at angles of attack between 30 deg and 40 deg (depending on c.g. location and flap setting). Hinge-moment data showed no regions with adverse effects on stick force. Comparisons of wind-tunnel data and flight-test are presented.
Soderman, P. T.↗
Engineering Development Program of a Closed Aluminum-Oxygen Semi-cell System for an Unmanned Underwater Vehicle: An Update
Most emerging unmanned undersea vehicle (UUV) missions require significantly longer range and endurance than is achievable with existing battery technology. The Aluminum-Oxygen (Al-O2) semi-cell is a candidate technology capable of providing a significant improvement in endurance compared to the silver-zinc battery technology currently in use in UUVs and compares favorably to other proposed UUV power systems not only in performance, but also in safety and logistics. An Al-O2 semi-cell system is under development, consisting of a cell stack, gas management, oxygen storage, electrolyte management coolant and controller subsystems. It is designed to replace the existing silver-zinc battery and meet existing weight, volume, electrical and thermal requirements, therefore minimizing modification to the UUV. A detailed system design is complete. A component and material endurance test to evaluate compatibility and reliability of various materials and components is complete. Sub=scale (short stack) system testing is complete. A full-scale demonstration unit is now under construction for testing in the second half of 1995. The full scale demonstration test will simulate environmental conditions of the operational system. This paper summarizes the results of the extensive short stack and endurance test programs, describes the plan for full-scale testing, and concludes with a brief discussion of future directions for this technology.
Gregg, Dane W.↗
USB environment measurements based on full-scale static engine ground tests
Flow turning parameters, static pressures, surface temperatures, surface fluctuating pressures and acceleration levels were measured in the environment of a full-scale upper surface blowing (USB) propulsive lift test configuration. The test components included a flightworthy CF6-50D engine, nacelle, and USB flap assembly utilized in conjunction with ground verification testing of the USAF YC-14 Advanced Medium STOL Transport propulsion system. Results, based on a preliminary analysis of the data, generally show reasonable agreement with predicted levels based on model data. However, additional detailed analysis is required to confirm the preliminary evaluation, to help delineate certain discrepancies with model data, and to establish a basis for future flight test comparisons.
Sussman, M. B.↗
Wind tunnel tests of a full-scale model of a light twin-engine airplane with fixed auxiliary airfoil or leading-edge slot
An investigation has been conducted by means of wind-tunnel tests of a full-scale mockup of a light twin-engine airplane configuration to determine the effects of outboard partial-span slots and of auxiliary airfoils ahead of the leading edge of the wing in improving aerodynamic characteristics at high angles of attack. Both of the stall-control devices gave considerable improvement in high angle-of-attack characteristics with the auxiliary airfoil giving the more favorable results, but neither device performed as well as might have been expected.
Fink, M. P.↗
Abradable compressor and turbine seals, volume 1
The application and advantages of abradable coatings as gas-path seals in a general aviation turbine engine were evaluated for use on the high-pressure compressor, the high-pressure turbine, and the low-pressure turbine shrouds. Topics covered include: (1) the initial selection of candidate materials for interim full-scale engine testing; (2) interim engine testing of the initially selected materials and additional candidate materials; (3) the design of the component required to adapt the hardware to permit full-scale engine testing of the most promising materials; (4) finalization of the fabrication methods used in the manufacture of engine test hardware; and (5) the manufacture of the hardware necessary to support the final full-scale engine tests.
Sundberg, D. V.↗
Full-Scale Wind-Tunnel Tests of a PCA-2 Autogiro Rotor
This report presents the results of force tests on and air-flow surveys near PCA-2 autogiro rotor in the NACA full-scale wind tunnel. The force tests were made at three pitch settings and several rotor speeds; the effect of fairing protuberances on the rotor blade was determined. Induced downwash and yaw angles were determined at low tip-speed ratios in a plane 1 1/2 feet above the path of the blade tips. The results show that the maximum l/d of the rotor cannot be appreciably increased by increasing the blade pitch angle above about 4.5 degrees at the blade tip; that the protuberances on the blades cause more than 5 percent of the total rotor drag; and that the rotor center-of-pressure travel is very small.
Wheatley, John B↗