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NASA Glenn Propulsion Systems Lab: 2012 Inaugural Ice Crystal Cloud Calibration Procedure and Results

The inaugural calibration of the ice crystal and supercooled liquid water clouds generated in NASA Glenn's engine altitude test facility, the Propulsion Systems Lab (PSL) is reported herein. This calibration was in support of the inaugural engine ice crystal validation test. During the Fall of 2012 calibration effort, cloud uniformity was documented via an icing grid, laser sheet and cloud tomography. Water content was measured via multi-wire and robust probes, and particle sizes were measured with a Cloud Droplet Probe and Cloud Imaging Probe. The environmental conditions ranged from 5,000 to 35,000 ft, Mach 0.15 to 0.55, temperature from +50 to -35 F and relative humidities from less than 1 percent to 75 percent in the plenum.

ice clouds

Smagglce: Surface Modeling and Grid Generation for Iced Airfoils: Phase 1 Results

SmaggIce (Surface Modeling and Grid Generation for Iced Airfoils) is a software toolkit used in the process of aerodynamic performance prediction of iced airfoils with grid-based Computational Fluid Dynamics (CFD). It includes tools for data probing, boundary smoothing, domain decomposition, and structured grid generation and refinement. SmaggIce provides the underlying computations to perform these functions, a GUI (Graphical User Interface) to control and interact with those functions, and graphical displays of results, it is being developed at NASA Glenn Research Center. This paper discusses the overall design of SmaggIce as well as what has been implemented in Phase 1. Phase 1 results provide two types of software tools: interactive ice shape probing and interactive ice shape control. The ice shape probing tools will provide aircraft icing engineers and scientists with an interactive means to measure the physical characteristics of ice shapes. On the other hand, the ice shape control features of SmaggIce will allow engineers to examine input geometry data, correct or modify any deficiencies in the geometry, and perform controlled systematic smoothing to a level that will make the CFD process manageable.

Vickerman, Mary B.

Analysis of the Honeywell Uncertified Research Engine (HURE) with Ice Crystal Cloud Ingestion at Simulated Altitudes

The Honeywell Uncertified Research Engine (HURE), a research version of a turbofan engine that never entered production, was tested in the NASA Propulsion System Laboratory (PSL), an altitude test facility at the NASA Glenn Research Center. The PSL is a facility that is equipped with water spray bars capable of producing an ice cloud consisting of ice particles, having a controlled particle diameter and concentration in the air flow. To develop the test matrix of the HURE, numerical analysis of flow and ice particle thermodynamics was performed on the compression system of the turbofan engine to predict operating conditions that could potentially result in a risk of ice accretion due to ice crystal ingestion. The goal of the test matrix was to have ice accrete in two regions of the compression system: region one, which consists of the fan-stator through the inlet guide vane (IGV), and region two which is the first stator within the high pressure compressor. The predictive analyses were performed with the mean line compressor flow modeling code (COMDES-MELT) which includes an ice particle model. The HURE engine was tested in PSL with the ice cloud over the range of operating conditions of altitude, ambient temperature, simulated flight Mach number, and fan speed with guidance from the analytical predictions. The engine was fitted with video cameras at strategic locations within the engine compression system flow path where ice was predicted to accrete, in order to visually confirm ice accretion when it occurred. In addition, traditional compressor instrumentation such as total pressure and temperature probes, static pressure taps, and metal temperature thermocouples were installed in targeted areas where the risk of ice accretion was expected. The current research focuses on the analysis of the data that was obtained after testing the HURE engine in PSL with ice crystal ingestion. The computational method (COMDES-MELT) was enhanced by computing key parameters through the fan-stator at multiple span wise locations, in order to increase the fidelity with the current mean-line method. The Icing Wedge static wet bulb temperature thresholds were applicable for determining the risk of ice accretion in the fan-stator, which is thought to be an adiabatic region. At some operating conditions near the splitter-lip region, other sources of heat (non-adiabatic walls) were suspected to be the cause of accretion, and the Icing Wedge was not applicable to predict accretion at that location. A simple order-of-magnitude heat transfer model was implemented into the COMDES-MELT code to estimate the wall temperature minimum and maximum thresholds that support ice accretion, as observed by video confirmation. The results from this model spanned the range of wall temperatures measured on a previous engine that experienced ice accretion at certain operating conditions.

Veres, Joseph P.

Analysis of the Honeywell Uncertified Research Engine (HURE) with Ice Crystal Cloud Ingestion at Simulated Altitudes

The Honeywell Uncertified Research Engine (HURE), a research version of a turbofan engine that never entered production, was tested in the NASA Propulsion System Laboratory (PSL), an altitude test facility at the NASA Glenn Research Center. The PSL is a facility that is equipped with water spray bars capable of producing an ice cloud consisting of ice particles, having a controlled particle diameter and concentration in the air flow. To develop the test matrix of the HURE, numerical analysis of flow and ice particle thermodynamics was performed on the compression system of the turbofan engine to predict operating conditions that could potentially result in a risk of ice accretion due to ice crystal ingestion. The goal of the test matrix was to have ice accrete in two regions of the compression system: region one, which consists of the fan-stator through the inlet guide vane (IGV), and region two which is the first stator within the high pressure compressor. The predictive analyses were performed with the mean line compressor flow modeling code (COMDES-MELT) which includes an ice particle model. The HURE engine was tested in PSL with the ice cloud over the range of operating conditions of altitude, ambient temperature, simulated flight Mach number, and fan speed with guidance from the analytical predictions. The engine was fitted with video cameras at strategic locations within the engine compression system flow path where ice was predicted to accrete, in order to visually confirm ice accretion when it occurred. In addition, traditional compressor instrumentation such as total pressure and temperature probes, static pressure taps, and metal temperature thermocouples were installed in targeted areas where the risk of ice accretion was expected. The current research focuses on the analysis of the data that was obtained after testing the HURE engine in PSL with ice crystal ingestion. The computational method (COMDES-MELT) was enhanced by computing key parameters through the fan- stator at multiple span wise locations, in order to increase the fidelity with the current mean-line method. The Icing Wedge static wet bulb temperature thresholds were applicable for determining the risk of ice accretion in the fan-stator, which is thought to be an adiabatic region. At some operating conditions near the splitter-lip region, other sources of heat (non-adiabatic walls) were suspected to be the cause of accretion, and the Icing Wedge was not applicable to predict accretion at that location. A simple order-of-magnitude heat transfer model was implemented into the COMDES-MELT code to estimate the wall temperature minimum and maximum thresholds that support ice accretion, as observed by video confirmation. The results from this model spanned the range of wall temperatures measured on a previous engine that experienced ice accretion at certain operating conditions.

Veres, Joseph P.

Analysis of the Honeywell Uncertified Research Engine (HURE) with Ice Crystal Cloud Ingestion at Simulated Altitudes: Public Version

The Honeywell Uncertified Research Engine (HURE), a research version of a turbofan engine that never entered production, was tested in the NASA Propulsion System Laboratory (PSL), an altitude test facility at the NASA Glenn Research Center. The PSL is a facility that is equipped with water spray bars capable of producing an ice cloud consisting of ice particles, having a controlled particle diameter and concentration in the air flow. In preparation for testing of the HURE, numerical analysis of flow and ice particle thermodynamics was performed on the compression system of the turbofan engine to predict operating conditions that could potentially result in a risk of ice accretion due to ice crystal ingestion. The results of those analyses formed the basis of the test matrix. The goal of the test matrix was to have ice accrete in two regions of the compression system: region one, which consists of the fan-stator through the inlet guide vane (IGV), and region two which is the first stator within the high pressure compressor. The predictive analyses were performed with the mean line compressor flow modeling code (COMDES-MELT) which includes an ice particle model. Together these comprise a one-dimensional icing tool. The HURE engine was tested in PSL with the ice cloud over the range of operating conditions of altitude, ambient temperature, simulated flight Mach number, and fan speed with guidance from the analytical predictions. The engine was fitted with video cameras at strategic locations within the engine compression system flow path where ice was predicted to accrete, in order to visually confirm ice accretion when it occurred. In addition, traditional compressor instrumentation such as total pressure and temperature probes, static pressure taps, and metal temperature thermocouples were installed in targeted areas where the risk of ice accretion was expected. The current research focuses on the analysis of the data that was obtained after testing the HURE engine in PSL with ice crystal ingestion. The computational method was enhanced by computing key parameters through the fan-stator at multiple spanwise locations, in order to increase the fidelity with the current mean-line method. In addition, other sources of heat (non-adiabatic walls) were suspected to be the cause of accretion near the splitter-lip and shroud. Since there were no thermocouples near the splitter, a simple order of magnitude heat transfer model was implemented to estimate the wall temperature. Future analyses will require a higher fidelity thermal analysis of the compression system metal walls to accurately calculate the total heat flux to the ice particle. For many data points analyzed, there were differences between the thermodynamic system model and the measured test data that may partially be responsible for uncertainties with the results of the current analyses.

Turbomachinery

Ice Crystal Icing Investigation on a Honeywell Uncertified Research Engine in an Altitude Simulation Icing Facility

A Honeywell Uncertified Research Engine was exposed to various ice crystal conditions in the NASA Glenn Propulsion Systems Laboratory. Simulations using NASA's 1D Icing Risk Analysis tool were used to determine potential inlet conditions that could lead to ice crystal accretion along the inlet of the core flowpath and into the high pressure compressor. These conditions were simulated in the facility to develop baseline conditions. Parameters were then varied to move or change accretion characteristics. Data were acquired at altitudes varying from 5 kft to 45 kft, at nominal ice particle Median Volumetric Diameters from 20 µm to 100 µm, and total water contents of 1 g/m3 to 12 g/m3. Engine and flight parameters such as fan speed, Mach number, and inlet temperature were also varied. The engine was instrumented with total temperature and pressure probes. Static pressure taps were installed at the leading edge of the fan stator, front frame hub, the shroud of the IGV, and first two rotors. Metal temperatures were acquired for vane stators 1-2. In-situ measurements of the particle size distribution were acquired three meters upstream of the engine forward fan flange and one meter downstream of the fan in the bypass in order to study particle break-up behavior. Cameras were installed in the engine to capture ice accretions at the leading edge of the fan stator, splitter lip, and inlet guide vane. Additional measurements acquired but not discussed in this paper include: high speed pressure transducers installed at the trailing edge of the first stage rotor and light extinction probes used to acquire particle concentrations at the fan exit stator plane and at the inlet to the core and bypass. The goal of this study was to understand key parameters of accretion, acquire particle break-up data aft of the fan, and generate a unique icing dataset for model and tool development. This work described in the paper focuses on the effect of particle break-up. It was found that there was significant particle break-up downstream of the fan in the bypass especially with larger initial particle sizes. The metal temperatures on the inlet guide vanes and stators show a temperature increase with increasing MVD. Accretion behavior was very similar across all test cases. However at the inlet guide vanes, the accretion decreased with increasing particle size.

Ashlie B Flegel

Experimental Water Droplet Impingement Data on Airfoils, Simulated Ice Shapes, an Engine Inlet and a Finite Wing

An experimental method has been developed to determine the water droplet impingement characteristics on two- and three-dimensional aircraft surfaces. The experimental water droplet impingement data are used to validate particle trajectory analysis codes that are used in aircraft icing analyses and engine inlet particle separator analyses. The aircraft surface is covered with thin strips of blotter paper in areas of interest. The surface is then exposed to an airstream that contains a dyed-water spray cloud. The water droplet impingement data are extracted from the dyed blotter paper strips by measuring the optical reflectance of each strip with an automated reflectometer. Experimental impingement efficiency data represented for a NLF (1)-0414 airfoil, a swept MS (1)-0317 airfoil, a Boeing 737-300 engine inlet model, two simulated ice shapes and a swept NACA 0012 wingtip. Analytical impingement efficiency data are also presented for the NLF (1)-0414 airfoil and the Boeing 737-300 engine inlet model.

Papadakis, M.

Near-term hybrid vehicle program, phase 1. Appendix D: Sensitivity analysis resport

Parametric analyses, using a hybrid vehicle synthesis and economics program (HYVELD) are described investigating the sensitivity of hybrid vehicle cost, fuel usage, utility, and marketability to changes in travel statistics, energy costs, vehicle lifetime and maintenance, owner use patterns, internal combustion engine (ICE) reference vehicle fuel economy, and drive-line component costs and type. The lowest initial cost of the hybrid vehicle would be $1200 to $1500 higher than that of the conventional vehicle. For nominal energy costs ($1.00/gal for gasoline and 4.2 cents/kWh for electricity), the ownership cost of the hybrid vehicle is projected to be 0.5 to 1.0 cents/mi less than the conventional ICE vehicle. To attain this ownership cost differential, the lifetime of the hybrid vehicle must be extended to 12 years and its maintenance cost reduced by 25 percent compared with the conventional vehicle. The ownership cost advantage of the hybrid vehicle increases rapidly as the price of fuel increases from $1 to $2/gal.

Source record

Software Testbed for Developing and Evaluating Integrated Autonomous Subsystems

To implement fault tolerant autonomy in future space systems, it will be necessary to integrate planning, adaptive control, and state estimation subsystems. However, integrating these subsystems is difficult, time-consuming, and error-prone. This paper describes Intelliface/ADAPT, a software testbed that helps researchers develop and test alternative strategies for integrating planning, execution, and diagnosis subsystems more quickly and easily. The testbed's architecture, graphical data displays, and implementations of the integrated subsystems support easy plug and play of alternate components to support research and development in fault-tolerant control of autonomous vehicles and operations support systems. Intelliface/ADAPT controls NASA's Advanced Diagnostics and Prognostics Testbed (ADAPT), which comprises batteries, electrical loads (fans, pumps, and lights), relays, circuit breakers, invertors, and sensors. During plan execution, an experimentor can inject faults into the ADAPT testbed by tripping circuit breakers, changing fan speed settings, and closing valves to restrict fluid flow. The diagnostic subsystem, based on NASA's Hybrid Diagnosis Engine (HyDE), detects and isolates these faults to determine the new state of the plant, ADAPT. Intelliface/ADAPT then updates its model of the ADAPT system's resources and determines whether the current plan can be executed using the reduced resources. If not, the planning subsystem generates a new plan that reschedules tasks, reconfigures ADAPT, and reassigns the use of ADAPT resources as needed to work around the fault. The resource model, planning domain model, and planning goals are expressed using NASA's Action Notation Modeling Language (ANML). Parts of the ANML model are generated automatically, and other parts are constructed by hand using the Planning Model Integrated Development Environment, a visual Eclipse-based IDE that accelerates ANML model development. Because native ANML planners are currently under development and not yet sufficiently capable, the ANML model is translated into the New Domain Definition Language (NDDL) and sent to NASA's EUROPA planning system for plan generation. The adaptive controller executes the new plan, using augmented, hierarchical finite state machines to select and sequence actions based on the state of the ADAPT system. Real-time sensor data, commands, and plans are displayed in information-dense arrays of timelines and graphs that zoom and scroll in unison. A dynamic schematic display uses color to show the real-time fault state and utilization of the system components and resources. An execution manager coordinates the activities of the other subsystems. The subsystems are integrated using the Internet Communications Engine (ICE). an object-oriented toolkit for building distributed applications.

Testbed

The Revolutionary Vertical Lift Technology (RVLT) Project

The Revolutionary Vertical Lift Technology (RVLT) Project is one of six projects in the Advanced Air Vehicles Program (AAVP) of the NASA Aeronautics Research Mission Directorate. The overarching goal of the RVLT Project is to develop and validate tools, technologies, and concepts to overcome key barriers for vertical lift vehicles. The project vision is to enable the next generation of vertical lift vehicles with aggressive goals for efficiency, noise, and emissions, to expand current capabilities and develop new commercial markets. The RVLT Project invests in technologies that support conventional, non-conventional, and emerging vertical-lift aircraft in the very light to heavy vehicle classes. Research areas include acoustic, aeromechanics, drive systems, engines, icing, hybrid-electric systems, impact dynamics, experimental techniques, computational methods, and conceptual design. The project research is executed at NASA Ames, Glenn, and Langley Research Centers; the research extensively leverages partnerships with the US Army, the Federal Aviation Administration, industry, and academia. The primary facilities used by the project for testing of vertical-lift technologies include the 14- by 22-Ft Wind Tunnel, Icing Research Tunnel, National Full-Scale Aerodynamics Complex, 7- by 10-Ft Wind Tunnel, Rotor Test Cell, Landing and Impact Research facility, Compressor Test Facility, Drive System Test Facilities, Transonic Turbine Blade Cascade Facility, Vertical Motion Simulator, Mobile Acoustic Facility, Exterior Effects Synthesis and Simulation Lab, and the NASA Advanced Supercomputing Complex. To learn more about the RVLT Project, please stop by booth #1004 or visit their website at https://www.nasa.gov/aeroresearch/programs/aavp/rvlt.

NASA

Evaluation of a Thermodynamic Ice Crystal Accretion Model using Experimental Data from NASA’s 2nd Fundamental Ice Crystal Icing Test

A thermodynamic model describing ice crystal icing is evaluated using experimental data collected at NASA Propulsion Systems Laboratory. The model makes the distinction between ice accretions that are "freeze-dominated" and "melt-dominated". Freeze-dominated icing occurs when partially melted ice crystals impact a surface and freeze. This type of icing is characterized by strong adhesion. This contrasts with melt-dominated icing, where un-melted ice crystals adhere to a surface. This type of icing is characterized by weak adhesion. In this paper, the thermodynamic model is used to analyze the ice growth rates and facility conditions to explain possible phenomena such as mass loss as well as the melting and freezing fractions. Previous analyses assumed a collection efficiency of unity at the leading edge of the experimental model. LEWICE is used to determine a better estimate of the collection efficiency at the model leading edge as ice accretion grows in time. The result shows that the sticking efficiency could change in a greater percent with time than previously reported.

Ice Crystal Icing

NASA Icing Update – May 2024

This presentation provides a status update on select NASA icing research activities for the SAE AC-9C Icing Technical Committee Meeting on May 6, 2024. The updates include the following topics: (1) Propulsion Systems Lab (PSL), (2) Adaptive Icing Tunnel (AIT), (3) Ice Adhesion / Deformed Skin Adhesion Test, (4) GlennICE, (5) Efficient Quiet Integrated Propulsor, (6) Icing Research Tunnel (IRT) CFD Characterization, and (7) Supercooled Large Droplet (SLD) Research.

Icing

NASA Icing Research Update 2024

This presentation summarizes NASA’s current icing research portfolio for an invited talk on August 1, 2024, at the AIAA Aviation Forum and Exposition. The presentation overviews NASA facilities, computational tools, and latest research. This research is categorized as application focused research, atmospheric characterization, and fundamental research / capability improvement. The application focused research includes (1) the Transonic Truss Brace Wing, (2) High Lift Common Research Model, (3) Advanced Air Mobility, and (4) Efficient Quiet Integrated Propulsor. The atmospheric characterization work includes High Ice Water Content Flight Research, while the fundamental research / capability improvement area includes (1) the Simulated Inter-compressor Duct Research Model, (2) Characterization of Low Ice Adhesion Materials, (3) Collection Efficiency Measurements, (4) Impedance Based Ice/ Water Sensor, (5) Tomography for Cloud Uniformity in the Icing Research Tunnel, and (6) Supercooled Large Drop Research. Finally, the presentation summarizes collaboration and partnership opportunities with NASA.

Icing

NASA Icing Update – Oct 2024

This presentation provides a status update on select NASA icing research activities for the SAE AC-9C Icing Technical Committee Meeting on Oct 21, 2024. The updates include the following topics: (1) Transonic Truss-Braced Wing Icing, (2) High-Lift Common Research Model Icing (3) Adaptive Icing Tunnel (AIT), (4) Advanced Air Mobility Icing, (5) GlennICE, (6) List of NASA Icing papers/presentations from 2024 AIAA Aviation Conference.

Icing

Ice-Crystal Icing Investigation on a Honeywell Uncertified Research Engine in an Altitude Simulation Icing Facility

A Honeywell Uncertified Research Engine was exposed to various ice-crystal conditions in the NASA Propulsion Systems Laboratory (PSL). Simulations using NASA's one-dimensional (1D) Icing Risk Analysis tool were used to determine potential inlet conditions that could lead to ice-crystal accretion along the inlet of the core flowpath and into the high-pressure compressor. Baseline conditions were established, and parameters were varied to observe accretion characteristics. Data were acquired at altitudes varying from 5 kft to 45 kft, at nominal ice particle median volumetric diameters from 20 µm to 100 µm, and total water contents of 1 g/m3 to 12 g/m3. Metal temperatures were acquired for the inlet guide vane and vane stators 1–2. In situ measurements of the particle size distribution were acquired upstream and downstream of the engine fan face in order to study particle breakup behavior. Cameras were installed in the engine to capture ice accretions at the leading edge of the fan stator, splitter lip, and inlet guide vane. The goal of this study was to understand the key parameters of accretion, acquire particle breakup data aft of the fan, and generate a unique icing dataset for model development. Significant particle breakup downstream of the fan in the bypass was observed. The metal temperatures on the inlet guide vanes (IGVs) and stators show a temperature increase with increasing particle size. Accretion behavior at the fan stator and splitter lip across was very similar. However, accretion decreased with increasing particle size at the IGVs.

Ashlie B. Flegel

Modeling of Highly Instrumented Honeywell Turbofan Engine Tested with Ice Crystal Ingestion in the NASA Propulsion System Laboratory

The Propulsion Systems Laboratory (PSL), an altitude test facility at NASA Glenn Research Center, has been used to test a highly instrumented turbine engine at simulated altitude operating conditions. This is a continuation of the PSL testing that successfully duplicated the icing events that were experienced in a previous engine (serial LF01) during flight through ice crystal clouds, which was the first turbofan engine tested in PSL. This second model of the ALF502R-5A serial number LF11 is a highly instrumented version of the previous engine. The PSL facility provides a continuous cloud of ice crystals with controlled characteristics of size and concentration, which are ingested by the engine during operation at simulated altitudes. Several of the previous operating points tested in the LF01 engine were duplicated to confirm repeatability in LF11. The instrumentation included video cameras to visually illustrate the accretion of ice in the low pressure compressor (LPC) exit guide vane region in order to confirm the ice accretion, which was suspected during the testing of the LF01. Traditional instrumentation included static pressure taps in the low pressure compressor inner and outer flow path walls, as well as total pressure and temperature rakes in the low pressure compressor region. The test data was utilized to determine the losses and blockages due to accretion in the exit guide vane region of the LPC. Multiple data points were analyzed with the Honeywell Customer Deck. A full engine roll back point was modeled with the Numerical Propulsion System Simulation (NPSS) code. The mean line compressor flow analysis code with ice crystal modeling was utilized to estimate the parameters that indicate the risk of accretion, as well as to estimate the degree of blockage and losses caused by accretion during a full engine roll back point. The analysis provided additional validation of the icing risk parameters within the LPC, as well as the creation of models for estimating the rates of blockage growth and losses.

Simulation

Analysis of aircraft engine blade subject to ice impact

The ice impact on the engine blade made of layered composite is simulated. The ice piece is modeled as an equivalent spherical object and has the velocity opposite to that of the aircraft with direction parallel to the engine axis. Near the impact region and along the leading edge, the blade is assumed to be fully stressed and undergoes large deflection. A specified portion of the blade around the impact region is modeled. The effect of ice size and velocity on the average leading edge strain are investigated for a modified SR-2 model unswept composite propfan blade. Parametric studies are performed to study the response due to ice impact at various locations along the span. Also, the effects of engine speed on the strain and impact displacements are discussed. It is found that for a given engine speed, a critical ice speed exists that corresponds to the maximum strain and this critical speed increases with increase in the engine speed.

Reddy, E. S.

Root damage analysis of aircraft engine blade subject to ice impact

The blade root response due to ice impact on an engine blade is simulated using the NASA in-house code BLASIM. The ice piece is modeled as an equivalent spherical object impacting on the leading edge of the blade and has the velocity opposite to that of the aircraft with direction parallel to the engine axis. The effect of ice impact is considered to be an impulse load on the blade with its amplitude computed based on the momentum transfer principle. The blade response due to the impact is carried out by modal superposition using the first three modes. The maximum dynamic stresses at the blade root are computed at the quarter cycle of the first natural frequency. A combined stress failure function based on modified distortion energy is used to study the spanwise bending damage response at the blade root. That damage function reaches maximum value for very low ice speeds and increases steeply with increases in engine speed.

Reddy, E. S.