Test plan for cold flow development test system
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Analysis of Probe Surveys Conducted in the 10-MW TP3 Arc-Jet Facility 15-Inch Nozzle Flow
Computational simulations and analysis of flow characterization tests in a high enthalpy arc-jet facility at NASA Ames Research Center are reported. These tests were conducted in the 10-MW TP3 facility 15-inch conical nozzle, and pitot pressure and heat flux probes are used to survey test flow downstream of the nozzle exit. Two 1.59-cm (0.625 in) diameter hemisphere probes were used: one with a stagnation-point pressure port, the other with a Gardon heat flux gage. Calibration data were also obtained using 20.32-cm flat-faced slug calorimeters. Experimental surveys of arc-jet test flow with pitot pressure and heat flux probes were obtained at eight arc-heater conditions, covering wide ranges in arc current (316–1756 A) and mass flow rate (32–500 g/s, without any cold-gas injection at the arc-heater plenum) and providing assessment of the flow uniformity in the facility. The present analysis comprises computational fluid dynamics simulations of the nonequilibrium flowfield in the facility nozzle and test box, including the models tested. These simulations take into account non-uniform total enthalpy and mass flux profiles at the nozzle inlet as well as the expansion waves emanating from the nozzle exit and their effects on the model flowfields. Comparisons of computations with the experimental measurements are presented, showing reasonably good agreement. The probe survey data and accompanying analysis show that the test flow in the TP3 15-inch nozzle is highly non-uniform at most conditions, and the extent of flow non-uniformity depends on arc current and mass flow rate.
Arc-jets↗
Analysis of Probe Surveys Conducted in the 10-MW TP3 Arc-Jet Facility 15-Inch Nozzle Flow
Computational simulations and analysis of flow characterization tests in a high enthalpy arc-jet facility at NASA Ames Research Center are reported. These tests were conducted in the 10-MW TP3 facility 15-inch conical nozzle, and pitot pressure and heat flux probes are used to survey test flow downstream of the nozzle exit. Two 1.59-cm (0.625 in) diameter hemisphere probes were used: one with a stagnation-point pressure port, the other with a Gardon heat flux gage. Calibration data were also obtained using 10.16-cm iso-q and 20.32-cm flat-faced slug calorimeters. Experimental surveys of arc-jet test flow with pitot pressure and heat flux probes were obtained at eight arc-heater conditions, covering wide ranges in arc current (316–1756 A) and mass flow rate (32–500 g/s, without any cold-gas injection at the arc-heater plenum) and providing assessment of the flow uniformity in the facility. The present analysis comprises computational fluid dynamics simulations of the nonequilibrium flowfield in the facility nozzle and test box, including the models tested. These simulations take into account non-uniform total enthalpy and mass flux profiles at the nozzle inlet as well as the expansion waves emanating from the nozzle exit and their effects on the model flowfields. Comparisons of computations with the experimental measurements are presented, showing reasonably good agreement. The probe survey data and accompanying analysis show that the test flow in the TP3 15-inch nozzle is highly non-uniform at most conditions, and the extent of flow non-uniformity depends on arc current and mass flow rate.
Arc-jets↗
Review of testing techniques and flow calibration results for hypersonic arc tunnels.
Hypersonic arc tunnels flow testing techniques, discussing heat transfer, contamination measurements, enthalpy fluctuations and baffle effects
Boatright, W. B.↗
Analysis and testing of compressible flow ejectors with variable area mixing tubes.
An analytical model has been developed to predict the flow behavior within axisymmetric single-nozzle ejectors employing variable-area mixing tubes. The primary flow may be supersonic or subsonic and may have a different stagnation temperature from the subsonic secondary flow. Tests were performed on an ejector with an 800 F supersonic (M = 2.72) primary jet to evaluate the analytical model. Measured velocity profiles, temperature profiles, and wall static pressure distributions are presented and compared to the analytical predictions. Agreement is generally good.
Hickman, K. E.↗
Design of a Crossflow Attenuated Natural Laminar Flow Flight Test Article
A natural laminar flow test article has been designed and analyzed for a flight test at the NASA Armstrong Flight Research Center using the F-15 aircraft with Centerline Instrument Pylon (CLIP) testbed. The flight test aims to experimentally validate the new Crossflow Attenuated Natural Laminar Flow (CATNLF) design method in a flight environment. The CATNLF design method uses geometry shaping to produce specific pressure distributions that enable laminar flow on vehicle components with high sweep and high Reynolds numbers by attenuating the crossflow growth that typically leads to premature transition on such components. The CATNLF test article, which will be mounted vertically below the F-15 for flight testing, is designed to be representative of a transonic transport wing and accounts for transition mechanisms due to crossflow, Tollmien-Schlichting, and attachment line transition instabilities. The test article is predicted to support 53% surface area of laminar flow on the suction-side at the design point and maintains significant laminar flow extents at near-cruise, off-design conditions. The design was performed, flight matrix selected, and instrumentation chosen with two primary test goals in mind: to confirm the effectiveness of the CATNLF method in attenuating crossflow growth on a representative transonic transport wing, and to investigate surface requirements needed for laminar flow applications.
Michelle N. Lynde↗
Tests of Cascades of Airfoils for Retarded Flow
Test results are present for cascades of airfoils in retarded flow and increasing pressure as corresponds to the case of the impeller of an axial propeller pump and propeller fan.
Shimoyama, Yoshinori↗
Evaluation of CFD as a Surrogate for Wind-Tunnel Testing: Experimental Uncertainty Quantification for the UPWT Flow Survey Test
A series of wind tunnel tests are being performed at the Unitary Plan Wind Tunnel (UPWT)at NASA Langley Research Center to assess the validity of using computational fluid dynamics(CFD) as a surrogate for wind tunnel testing. In order to make proper comparisons, uncertainties in CFD results and experimental data must be well understood. The material presented highlights the methods, assumptions, and inputs used to achieve experimental uncertainty estimates. Results for a small subset of tunnel conditions and variables of interest from the first test in the series, the Flow Survey Test, are highlighted and sample CFD comparisons are shown. The bulk of the results from this work are used for comparisons in other AIAA conference papers related to this test series.
Erin P Hubbard↗
Hot-Film and Hot-Wire Anemometry for a Boundary Layer Active Flow Control Test
Unsteady active flow control (AFC) has been used experimentally for many years to minimize bluff-body drag. This technology could significantly improve performance of rotorcraft by cleaning up flow separation. It is important, then, that new actuator technologies be studied for application to future vehicles. A boundary layer wind tunnel was constructed with a 1ft-x-3ft test section and unsteady measurement instrumentation to study how AFC manipulates the boundary layer to overcome adverse pressure gradients and flow separation. This unsteady flow control research requires unsteady measurement methods. In order to measure the boundary layer characteristics, both hot-wire and hot-film Constant Temperature Anemometry is used. A hot-wire probe is mounted in the flow to measure velocity while a hot-film array lays on the test surface to measure skin friction. Hot-film sensors are connected to an anemometer, a Wheatstone bridge circuit with an output that corresponds to the dynamic flow response. From this output, the time varying flow field, turbulence, and flow reversal can be characterized. Tuning the anemometers requires a fan test on the hot-film sensors to adjust each output. This is a delicate process as several variables drastically affect the data, including control resistance, signal input, trim, and gain settings.
Control Test↗
Flow Characterization Studies of the 10-MW TP3 Arc-Jet Facility: Probe Sweeps
This paper reports computational simulations and analysis in support of calibration and flow characterization tests in a high enthalpy arc-jet facility at NASA Ames Research Center. These tests were conducted in the NASA Ames 10-MW TP3 facility using flat-faced stagnation calorimeters at six conditions corresponding to the steps of a simulated flight heating profile. Data were obtained using a conical nozzle test configuration in which the models were placed in a free jet downstream of the nozzle. Experimental surveys of arc-jet test flow with pitot pressure and heat flux probes were also performed at these arc-heater conditions, providing assessment of the flow uniformity and valuable data for the flow characterization. Two different sets of pitot pressure and heat probes were used: 9.1-mm sphere-cone probes (nose radius of 4.57 mm or 0.18 in) with null-point heat flux gages, and 15.9-mm (0.625 in) diameter hemisphere probes with Gardon gages. The probe survey data clearly show that the test flow in the TP3 facility is not uniform at most conditions (not even axisymmetric at some conditions), and the extent of non-uniformity is highly dependent on various arc-jet parameters such as arc current, mass flow rate, and the amount of cold-gas injection at the arc-heater plenum. The present analysis comprises computational fluid dynamics simulations of the nonequilibrium flowfield in the facility nozzle and test box, including the models tested. Comparisons of computations with the experimental measurements show reasonably good agreement except at the extreme low pressure conditions of the facility envelope.
Goekcen, Tahir↗
Flow Characterization Studies of the 10-MW TP3 Arc-Jet Facility: Probe Sweeps
This paper reports computational simulations and analysis in support of calibration and flow characterization tests in a high enthalpy arc-jet facility at NASA Ames Research Center. These tests were conducted in the NASA Ames 10-MW TP3 facility using flat-faced stagnation calorimeters at six conditions corresponding to the steps of a simulated flight heating profile. Data were obtained using a conical nozzle test configuration in which the models were placed in a free jet downstream of the nozzle. Experimental surveys of arc-jet test flow with pitot pressure and heat flux probes were also performed at these arc-heater conditions, providing assessment of the flow uniformity and valuable data for the flow characterization. Two different sets of pitot pressure and heat probes were used: 9.1-mm sphere-cone probes (nose radius of 4.57 mm or 0.18 in) with null-point heat flux gages, and 15.9-mm (0.625 in) diameter hemisphere probes with Gardon gages. The probe survey data clearly show that the test flow in the TP3 facility is not uniform at most conditions (not even axisymmetric at some conditions), and the extent of non-uniformity is highly dependent on various arc-jet parameters such as arc current, mass flow rate, and the amount of cold-gas injection at the arc-heater plenum. The present analysis comprises computational fluid dynamics simulations of the nonequilibrium flowfield in the facility nozzle and test box, including the models tested. Comparisons of computations with the experimental measurements show reasonably good agreement except at the extreme low pressure conditions of the facility envelope.
CFD↗
Study and development of an air conditioning system operating on a magnetic heat pump cycle (design and testing of flow directors)
This report describes the fabrication, design of flow director, fluid flow direction analysis and testing of flow director of a magnetic heat pump. The objectives of the project are: (1) to fabricate a demonstration magnetic heat pump prototype with flow directors installed; and (2) analysis and testing of flow director and to make sure working fluid loops flow through correct directions with minor mixing. The prototype was fabricated and tested at the Development Testing Laboratory of Kennedy Space Center. The magnetic heat pump uses rear earth metal plates rotate in and out of a magnetic field in a clear plastic housing with water flowing through the rotor plates to provide temperature lift. Obtaining the proper water flow direction has been a problem. Flow directors were installed as flow barriers between separating point of two parallel loops. Function of flow directors were proven to be excellent both analytically and experimentally.
Wang, Pao-Lien↗
Recent Ground-based Test Results for the Closed Loop Two-Phase Flow Chilldown Test Module for Future Integration with the Flow Boiling and Condensation Experiment onboard International Space Station
Effective cryogenic fluid management is important to the success of future manned and unmanned NASA missions, and the transfer line chilldown process is recognized as a key technological challenge. To address this challenge, the Two-phase Flow and Thermal Management Lab (TFTML) at Case Western Reserve University is collaborating with NASA Glenn Research Center to develop, test and deploy a closed loop two-phase flow chilldown test section onboard the International Space Station to be integrated with the current Flow Boiling and Condensation Experiment (FBCE) module. The final results of this project will create the first chilldown process database under pure and sustained microgravity conditions and will significantly advance the understanding of the chilldown process for cryogenic fluid management. In the present work, the ground-based test results of the closed loop SS-316 chilldown test section in a horizontal configuration at varying inlet mass flow rates (3-40 g/s) and inlet liquid subcooling (5-35 0C) are presented. The working fluid is PF-5060 and the chilldown curves captured the entire quenching curve involving the different boiling regimes and temperature transition points viz., film boiling, Leidenfrost/re-wetting point, transition boiling, critical heat flux (CHF), nucleate boiling, onset of nucleate boiling (ONB) and single-phase liquid flow regions, when the test section is pre-heated to around 250 0C. The major findings of the present study are, (i) the bottom part of the test section sees a lower re-wetting temperature due to the horizontal flow configuration, (ii) the re-wetting temperatures are relatively unaffected by inlet liquid mass flow rates though the increase in mass flow rates reduce the chilldown time, and (iii) the re-wetting temperatures decrease with decrease in inlet liquid subcooling. Further, preliminary flow visualization studies in a transparent pyrex test section will also be presented to understand the intricate flow boiling regime transitions during the chilldown process.
ISS↗
NASA Ares I Launch Vehicle Upper Stage Reaction Control System (ReCS) Cold Flow Development Test Overview
NASA s Ares I launch vehicle, consisting of a five segment solid rocket booster first stage and a liquid bi-propellant J2-X engine Upper Stage, is the vehicle that s been chosen to launch the Orion Crew Module, which will return humans to the Moon, Mars, and beyond. After First Stage booster separation, the Reaction Control System (ReCS), a monopropellant hydrazine system, will provide the Upper Stage element with three degrees of freedom control as needed. This paper provides an overview of the system level development testing that has taken place on the Ares I launch vehicle Upper Stage ReCS. The ReCS System Development Test Article (SDTA) was built as a flight representative water flow test article whose primary test objective was to obtain fluid system performance data to evaluate the integrate system performance characteristics and verify analytical models. Water is the industry standard for cold flow testing of hydrazine systems, because the densities are very close and the speeds of sound are well characterized. The completion of this development level test program was considered necessary to support the ReCS Critical Design Review. This paper will address the design approach taken in building the test article, the objectives of the test program, types of testing completed, general results, the ability of the program to meet the test objectives, and lessons learned
Dervan, Melanie↗
Performance and test section flow characteristics of the National Full-Scale Aerodynamics Complex 40- by 80-foot wind tunnel
Results from the performance and test section flow calibration of the 40- by 80-Foot Wind Tunnel are presented. A flow calibration test was conducted in May and June 1987. The goal of the flow calibration test was to determine detailed spatial variations in the 40- by 80-ft test section flow quality throughout the tunnel operational envelope. Data were collected for test section speeds up to 300 knots and for air exchange rates of 0, 5, and 10 percent. The tunnel performance was also calibrated during the detailed mapping of the test section flow field. Experimental results presented indicate that the flow quality in the test section, with the exception of temperature, is relatively insensitive to the level of dynamic pressure and the air exchange rate. The dynamic pressure variation in the test section is within + or - 0.5 deg at all test section velocities. Cross-stream temperature gradients in the test section caused by the air exchange system were documented, and a correction method was established. Streamwise static pressure variation on the centerline is about 1 percent of test section dynamic pressure over 30 ft of the test section length.
Zell, Peter T.↗
Oscillating-flow loss test results in rectangular heat exchanger passages
Test results of oscillating flow losses in rectangular heat exchanger passages of various aspect ratios are given. This work was performed in support of the design of a free-piston Stirling engine (FPSE) for a dynamic space power conversion system. Oscillating flow loss testing was performed using an oscillating flow rig, which was based on a variable stroke and variable frequency linear drive motor. Tests were run over a range of oscillating flow parameters encompassing the flow regimes of the proposed engine design. Test results are presented in both tabular and graphical form and are compared against analytical predictions.
Wood, J. Gary↗
HYPERFIRE
The two main sub-scale, ground-based rocket aerodynamics testing techniques – hot-fire testing and cold-flow testing – pose a series of tradeoffs. Hot-fire testing is generally much more accurate, but is often burdensome, costly, and requires long lead times due to design work, infrastructure preparation, etc. Cold-flow testing is much less expensive and has a rapid turnaround time, but conventional simulants (e.g., nitrogen, steam) used in cold-flow testing yield less accurate results (i.e., results that are not sufficiently representative of test article performance). While researching methods to optimize such tradeoffs, engineers at NASA’s Stennis Space Center discovered that ethane can be tuned to approximate rocket exhaust plumes generated by several common rocket propellants. This led NASA to develop the HYdrocarbon Propellants Enabling Reproduction of Flows in Rocket Engines (HYPERFIRE), a sub-scale, non-reacting flow test system. HYPERFIRE uses heated ethane to enable physical simulation of rocket engines powered by a broad range of propellants in an inexpensive, accurate, and simple fashion.
sub-scale↗
Operation manual for the NOTS-NASA Rocket- Motor Acoustic Test Facility steady-state resonance tests with flow
Operation manual for steady state resonance tests through flow at rocket motor acoustic test facility
Buffum, F. G.↗