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NASA NTRS1998

Langley Aerothermodynamic Facilities Complex: Enhancements and Testing Capabilities

Description, capabilities, recent upgrades, and utilization of the NASA Langley Research Center (LaRC) Aerothermodynamic Facilities Complex (AFC) are presented. The AFC consists of five hypersonic, blow-down-to-vacuum wind tunnels that collectively provide a range of Mach number from 6 to 20, unit Reynolds number from 0.04 to 22 million per foot and, most importantly for blunt configurations, normal shock density ratio from 4 to 12. These wide ranges of hypersonic simulation parameters are due, in part, to the use of three different test gases (air, helium, and tetrafluoromethane), thereby making several of the facilities unique. The Complex represents nearly three-fourths of the conventional (as opposed to impulse)-type hypersonic wind tunnels operational in this country. AFC facilities are used to assess and optimize the hypersonic aerodynamic performance and aeroheating characteristics of aerospace vehicle concepts and to provide benchmark aerodynamic/aeroheating data fr generating the flight aerodynamic databook and final design of the thermal protection system (TPS) (e.g., establishment of flight limitations not to exceed TPS design limits). Modifications and enhancements of AFC hardware components and instrumentation have been pursued to increase capability, reliability, and productivity in support of programmatic goals. Examples illustrating facility utilization in recent years to generate essentially all of the experimental hypersonic aerodynamic and aeroheating information for high-priority, fast-paced Agency programs are presented. These programs include Phase I of the Reusable Launch Vehicle (RLV) Advanced Technology Demonstrator, X-33 program, PHase II of the X-33 program, X-34 program, the Hyper-X program ( a Mach 5,7, and 10 airbreathing propulsion flight experiment), and the X-38 program (Experimental Crew Return Vehicle, X-CRV). Current upgrades/enchancements and future plans for the AFC are discussed.

Micol, J. R.↗

NASA NTRS1998

Aerothermodynamic Flight Simulation Capabilities for Aerospace Vehicles

Aerothermodynamics, encompassing aerodynamics, aeroheating, and fluid dynamics and physical processes, is the genesis for the design and development of advanced space transportation vehicles and provides crucial information to other disciplines such as structures, materials, propulsion, avionics, and guidance, navigation and control. Sources of aerothermodynamic information are ground-based facilities, Computational Fluid Dynamic (CFD) and engineering computer codes, and flight experiments. Utilization of this aerothermodynamic triad provides the optimum aerothermodynamic design to safely satisfy mission requirements while reducing design conservatism, risk and cost. The iterative aerothermodynamic process for initial screening/assessment of aerospace vehicle concepts, optimization of aerolines to achieve/exceed mission requirements, and benchmark studies for final design and establishment of the flight data book are reviewed. Aerothermodynamic methodology centered on synergism between ground-based testing and CFD predictions is discussed for various flow regimes encountered by a vehicle entering the Earth s atmosphere from low Earth orbit. An overview of the resources/infrastructure required to provide accurate/creditable aerothermodynamic information in a timely manner is presented. Impacts on Langley s aerothermodynamic capabilities due to recent programmatic changes such as Center reorganization, downsizing, outsourcing, industry (as opposed to NASA) led programs, and so forth are discussed. Sample applications of these capabilities to high Agency priority, fast-paced programs such as Reusable Launch Vehicle (RLV)/X-33 Phases I and 11, X-34, Hyper-X and X-38 are presented and lessons learned discussed. Lastly, enhancements in ground-based testing/CFD capabilities necessary to partially/fully satisfy future requirements are addressed.

Miller, Charles G.↗

NASA NTRS1998

Dual Mode Shock-Expansion/Reflected-Shock Tunnel

NASA s HYPULSE facility at GASL has been reconfigured to permit free jet testing of the Hyper-X flowpath at flight Mach numbers of 7 and 10. Among the required changes are addition of a converging-diverging nozzle to permit operation in a reflected shock tunnel mode, a 7 ft. diameter test cabin and a 30 in. diameter contoured nozzle. However, none of these changes were allowed to interfere with rapid recovery of the prior shock-expansion tunnel mode of operation, and indeed certain changes should enhance facility usefulness and productivity in either mode. A previously-developed shock-induced detonation mode of driving the facility has been successfully applied to both reflected shock tunnel operation at Mach 10 flight conditions, with tailored interface operation, and shock-expansion tunnel operation at flight conditions corresponding to Mach numbers from 12 to 25. Tailored interface operation at Mach 7 has been achieved with an unheated helium driver. In the present paper, the rationale for a dual mode shock expansion/reflected shock tunnel is discussed, and the capabilities and limitations for each mode are outlined. The physical changes in the HYPULSE facility to achieve dual mode capability are also described. Limited calibration data obtained to date in the new reflected shock tunnel mode are presented and the anticipated flight simulation map with dual mode operation is also outlined.

Erdos, John I.↗

NASA NTRS2004

Modeling Compressibility Effects in High-Speed Turbulent Flows

Man has strived to make objects fly faster, first from subsonic to supersonic and then to hypersonic speeds. Spacecraft and high-speed missiles routinely fly at hypersonic Mach numbers, M greater than 5. In defense applications, aircraft reach hypersonic speeds at high altitude and so may civilian aircraft in the future. Hypersonic flight, while presenting opportunities, has formidable challenges that have spurred vigorous research and development, mainly by NASA and the Air Force in the USA. Although NASP, the premier hypersonic concept of the eighties and early nineties, did not lead to flight demonstration, much basic research and technology development was possible. There is renewed interest in supersonic and hypersonic flight with the HyTech program of the Air Force and the Hyper-X program at NASA being examples of current thrusts in the field. At high-subsonic to supersonic speeds, fluid compressibility becomes increasingly important in the turbulent boundary layers and shear layers associated with the flow around aerospace vehicles. Changes in thermodynamic variables: density, temperature and pressure, interact strongly with the underlying vortical, turbulent flow. The ensuing changes to the flow may be qualitative such as shocks which have no incompressible counterpart, or quantitative such as the reduction of skin friction with Mach number, large heat transfer rates due to viscous heating, and the dramatic reduction of fuel/oxidant mixing at high convective Mach number. The peculiarities of compressible turbulence, so-called compressibility effects, have been reviewed by Fernholz and Finley. Predictions of aerodynamic performance in high-speed applications require accurate computational modeling of these "compressibility effects" on turbulence. During the course of the project we have made fundamental advances in modeling the pressure-strain correlation and developed a code to evaluate alternate turbulence models in the compressible shear layer.

Sarkar, S.↗

NASA NTRS2005

Scramjet Development Tests Supporting the Mach 10 Flight of the X-43

The Hyper-X Project s successful third flight of the X-43 at near Mach 10 in 2004 proved the potential for airbreathing propulsion at hypersonic speeds. The engine flowpath used in the X-43 research vehicle was developed and evaluated in a systematic series of ground tests in the NASA HyPulse Shock Tunnel at conditions duplicating Mach 10 flight using a full scale height, partial width engine model of the flight engine. Tests were conducted over a range of equivalence ratios from 0.8 to 1.6 using hydrogen and a mixture of two-percent silane in hydrogen fuels. Silane gas was used as an ignition aid during the short duration of the pulse facility tests. Variation of the engine inflow conditions, pressure, temperature, and Mach number, were parametrically varied during the test entries to broaden the database over the expected uncertainty in the flight conditions. A review of the ground test technique and comparisons of the ground test pressures along with selected flight data are presented.

Rogers, R. C.↗

NASA NTRS2005

X-43A Fluid and Environmental Systems: Ground and Flight Operation and Lessons Learned

The X-43A Hyper-X program demonstrated the first successful flights of an airframe integrated scramjet powered hypersonic vehicle. The X-43A vehicles established successive world records for jet-powered vehicles at speeds of Mach 7 and Mach 10. The X-43A vehicle is a subscale version of proposed hypersonic reconnaissance strike aircraft. Scaled down to a length of 12 ft (3.66 m), the lifting body design with high fineness ratio resulted in very small internal space available for fluid systems and their corresponding environmental conditioning systems. Safe testing and operation of the X-43A fluid and environmental systems was critical for mission success, not only for the safety of the flight crew in the NASA B-52B carrier aircraft, but also to maintain the reliability of vehicle systems while exposed to dynamics and hostile conditions encountered during the boost trajectory. The X-43A fluid and environmental systems successfully managed explosive, pyrophoric, inert, and very high pressure gases without incident. This report presents a summary of the checkout and flight validation of the X-43A fluid systems. The testing used for mission assurance is summarized. System performance during captive carry and launch flights is presented. The lessons learned are also discussed.

Vachon, Michael Jacob↗

NASA NTRS2005

Development of X-43A Mach 10 Leading Edges

The nose leading edge of the Hyper-X Mach 10 vehicle was orginally anticipated to reach temperatures near 4000 F at the leading-edge stagnation line. A SiC coated carbon/carbon (C/C) leading-edge material will not survive that extreme temperature for even a short duration single flight. To identify a suitable leading edge for the Mach 10 vehicle, arc-jet testing was performed on thirteen leading-edge segments fabricated from different material systems to evaluate their performance in a simulated flight environment. Hf, Zr, Si, and Ir based materials, in most cases as a coating on C/C, were included in the evaluation. Afterwards, MER, Tucson, AZ was selected as the supplier of the flight vehicle leading edges. The nose and the vertical and horizontal tail leading edges were fabricated out of a 3:1 biased high thermal conductivity C/C. The leading edges were coated with a three layer coating comprised of a SiC conversion of the top surface of the C/C, followed by a chemical vapor deposited layer of SiC, followed by a thin chemical vapor deposited layer of HfC. This paper will describe the fabrication of the Mach 10 C/C leading edges and the testing performed to validate performance.

Ohlhorst, Craig W.↗

NASA NTRS2006

X-43A Flight Controls

A viewgraph presentation detailing X-43A Flight controls at NASA Dryden Flight Research Center is shown. The topics include: 1) NASA Dryden, Overview and current and recent flight test programs; 2) Unmanned Aerial Vehicle Synthetic Aperture Radar (UAVSAR) Program, Program Overview and Platform Precision Autopilot; and 3) Hyper-X Program, Program Overview, X-43A Flight Controls and Flight Results.

Baumann, Ethan↗

NASA NTRS2006

Flight-Test-Determined Aerodynamic Force and Moment Characteristics of the X-43A at Mach 7.0

The second flight of the Hyper-X program afforded a unique opportunity to determine the aerodynamic force and moment characteristics of an airframe-integrated scramjet-powered aircraft in hypersonic flight. These data were gathered via a repeated series of pitch, yaw, and roll doublets; frequency sweeps; and pushover-pullup maneuvers performed throughout the X-43A cowl-closed descent. Maneuvers were conducted at Mach numbers of 6.80 to 0.95 and altitudes from 92,000 ft msl to sea level. The dynamic pressure varied from 1300 psf to 400 psf with the angle of attack ranging from 0 deg to 14 deg. The flight-extracted aerodynamics were compared with preflight predictions based on wind-tunnel-test data. The X-43A flight-derived axial force was found to be 10 percent to 15 percent higher than prediction. Under-predictions of similar magnitude were observed for the normal force. For Mach numbers above 4.0, the flight-derived stability and control characteristics resulted in larger-than-predicted static margins, with the largest discrepancy approximately 5 in. forward along the x-axis center of gravity at Mach 6.0. This condition would result in less static margin in pitch. The predicted lateral-directional stability and control characteristics matched well with flight data when allowance was made for the high uncertainty in angle of sideslip.

Davis. Marl C.↗

NASA NTRS2007

Discrete Roughness Transition for Hypersonic Flight Vehicles

The importance of discrete roughness and the correlations developed to predict the onset of boundary layer transition on hypersonic flight vehicles are discussed. The paper is organized by hypersonic vehicle applications characterized in a general sense by the boundary layer: slender with hypersonic conditions at the edge of the boundary layer, moderately blunt with supersonic, and blunt with subsonic. This paper is intended to be a review of recent discrete roughness transition work completed at NASA Langley Research Center in support of agency flight test programs. First, a review is provided of discrete roughness wind tunnel data and the resulting correlations that were developed. Then, results obtained from flight vehicles, in particular the recently flown Hyper-X and Shuttle missions, are discussed and compared to the ground-based correlations.

Berry, Scott A.↗

NASA NTRS2007

The Road to Mach 10: A History of the X-43A Hypersonic Flight Test Program at NASA Dryden...Toward the Future

In terms of technology, the X-43A/Hyper-X represented a singular milestone. After nearly a half century of high hopes, studies, wind tunnel tests, proposals, and canceled projects, a scramjet-powered vehicle had flown. The performance of the engine qualified the scramjet design tools and scaling laws. In turn, the theoretical calculations and ground testing could be used to design more advanced engine concepts. Just as important, both the scramjet and vehicle systems had successfully operated in the variable temperatures and densities of the atmosphere. The X-43A systems were able to maintain the exact flight conditions necessary for the scramjet to operate properly. Control deflections to correct the engine-induced moments were close to pre-flight predictions. When the unexpected occurred, such as when the vehicle pitched up during the cowl opening on the second flight, the control system was sufficiently designed to correct the situation. The airframe and wing structure, the thermal protection material, and the internal conditions of the X-43A performed largely as predicted. The HXLV thermal anomaly during the ascent on the third flight and "the Mach 8 unpleasantness" during the descent indicated that the HXLV and X-43A were not as resilient to aerodynamic heating as expected. The X-43A 's airframe drag and lift both were slightly higher than predicted, but still within preflight uncertainty predictions. The stability and control were as predicted, as was the boundary layer transition. The biggest aerodynamic worry before the flight was the separation of the HXLV and the X- 43A. After all was said and done, this went exactly as predicted, proving that non-symmetrical/high-dynamic pressure stage separations could be performed. This in turn meant that two-stage-to-orbit vehicles employing this technology were feasible. The Hyper-X program also served as a training ground for a new generation of scramjet and hypersonic researchers. This included both NASA and contractor personnel, providing them with experience in ground testing and component development; vehicle design, construction, integration, system checkout, and, ultimately, flight testing and data analysis. Additionally, researchers learned the practical details of running a project within finite budget and time limits, about the ambiguousness of risk assessment, and about the need to spend a significant amount of time and effort dealing with engineering problems, such as those with the FAS, that have nothing to do with the project's research goals. Finally, all those who worked on the X-43A project now know what it is like to spend years transforming an idea into a functional vehicle, only for it to be lost in a matter of seconds. And then to go through years of work to correct the problems, to face the possibility that still more might exist, and finally to savor the triumph of two successful flights. For those who will work on the hypersonic projects that emerge in coming years, these experiences may prove to be the most valuable of all.

Peebles, Curtis↗

NASA NTRS2008

Flight Test Experiment Design for Characterizing Stability and Control of Hypersonic Vehicles

A maneuver design method that is particularly well-suited for determining the stability and control characteristics of hypersonic vehicles is described in detail. Analytical properties of the maneuver design are explained. The importance of these analytical properties for maximizing information content in flight data is discussed, along with practical implementation issues. Results from flight tests of the X-43A hypersonic research vehicle (also called Hyper-X) are used to demonstrate the excellent modeling results obtained using this maneuver design approach. A detailed design procedure for generating the maneuvers is given to allow application to other flight test programs.

Morelli, Eugene A.↗

NASA NTRS2008

Aeroservoelastic Stability Analysis of the X-43A Stack

The first air launch attempt of an X-43A stack, consisting of the booster, adapter and Hyper-X research vehicle, ended in failure shortly after the successful drop from the National Aeronautics and Space Administration Dryden Flight Research Center (Edwards, California) B-52B airplane and ignition of the booster. The stack was observed to begin rolling and yawing violently upon reaching transonic speeds, and the grossly oscillating fins of the booster separated shortly thereafter. The flight then had to be terminated with the stack out of control. Very careful linear flutter and aeroservoelastic analyses were subsequently performed as reported herein to numerically duplicate the observed instability. These analyses properly identified the instability mechanism and demonstrated the importance of including the flight control laws, rigid-body modes, structural flexible modes and control surface flexible modes. In spite of these efforts, however, the predicted instability speed remained more than 25 percent higher than that observed in flight. It is concluded that transonic shock phenomena, which linear analyses cannot take into account, are also important for accurate prediction of this mishap instability.

Pak, Chan-gi↗

NASA NTRS2007

Discrete Roughness Transition for Hypersonic Flight Vehicles

Berry, Scott A.↗

NASA NTRS2008

X-43A Flight-Test-Determined Aerodynamic Force and Moment Characteristics at Mach 7.0

The second flight of the Hyper-X program afforded a unique opportunity to determine the aerodynamic force and moment characteristics of an airframe-integrated scramjet-powered aircraft in hypersonic flight. These data were gathered via a repeated series of pitch, yaw, and roll doublets, frequency sweeps, and pushover-pullup maneuvers performed throughout the X-43A cowl-closed descent. Maneuvers were conducted at Mach numbers of 6.80-0.95 and at altitudes from 92,000 ft mean sea level to sea level. The dynamic pressure varied from 1300 to 400 psf with the angle of attack ranging from 0 to 14 deg. The flight-extracted aerodynamics were compared with preflight predictions based on wind-tunnel test data. The X-43A flight-derived axial force was found to be 10-15%higher than prediction. Underpredictions of similar magnitude were observed for the normal force. For Mach numbers above 4.0, the flight-derived stability and control characteristics resulted in larger-than-predicted static margins, with the largest discrepancy approximately 5 in. forward along the x-axis center of gravity at Mach 6.0. This condition would result in less static margin in pitch. The predicted lateral-directional stability and control characteristics matched well with flight data when allowance was made for the high uncertainty in angle of sideslip.

Davis, Mark C.↗

NASA NTRS2008

PLIF Visualization of Active Control of Hypersonic Boundary Layers Using Blowing

Planar laser-induced fluorescence (PLIF) imaging was used to visualize the boundary layer flow on a 1/3-scale Hyper-X forebody model. The boundary layer was perturbed by blowing out of orifices normal to the model surface. Two blowing orifice configurations were used: a spanwise row of 17-holes spaced at 1/8 inch, with diameters of 0.020 inches and a single-hole orifice with a diameter of 0.010 inches. The purpose of the study was to visualize and identify laminar and turbulent structures in the boundary layer and to make comparisons with previous phosphor thermography measurements of surface heating. Jet penetration and its influence on the boundary layer development was also examined as was the effect of a compression corner on downstream boundary layer transition. Based upon the acquired PLIF images, it was determined that global surface heating measurements obtained using the phosphor thermography technique provide an incomplete indicator of transitional and turbulent behavior of the corresponding boundary layer flow. Additionally, the PLIF images show a significant contribution towards transition from instabilities originating from the underexpanded jets. For this experiment, a nitric oxide/nitrogen mixture was seeded through the orifices, with nitric oxide (NO) serving as the fluorescing gas. The experiment was performed in the 31-inch Mach 10 Air Tunnel at NASA Langley Research Center.

Bathel, Brett F.↗

NASA NTRS2008

Stereoscopic Imaging in Hypersonics Boundary Layers using Planar Laser-Induced Fluorescence

Stereoscopic time-resolved visualization of three-dimensional structures in a hypersonic flow has been performed for the first time. Nitric Oxide (NO) was seeded into hypersonic boundary layer flows that were designed to transition from laminar to turbulent. A thick laser sheet illuminated and excited the NO, causing spatially-varying fluorescence. Two cameras in a stereoscopic configuration were used to image the fluorescence. The images were processed in a computer visualization environment to provide stereoscopic image pairs. Two methods were used to display these image pairs: a cross-eyed viewing method which can be viewed by naked eyes, and red/blue anaglyphs, which require viewing through red/blue glasses. The images visualized three-dimensional information that would be lost if conventional planar laser-induced fluorescence imaging had been used. Two model configurations were studied in NASA Langley Research Center's 31-Inch Mach 10 Air Wind tunnel. One model was a 10 degree half-angle wedge containing a small protuberance to force the flow to transition. The other model was a 1/3-scale, truncated Hyper-X forebody model with blowing through a series of holes to force the boundary layer flow to transition to turbulence. In the former case, low flowrates of pure NO seeded and marked the boundary layer fluid. In the latter, a trace concentration of NO was seeded into the injected N2 gas. The three-dimensional visualizations have an effective time resolution of about 500 ns, which is fast enough to freeze this hypersonic flow. The 512x512 resolution of the resulting images is much higher than high-speed laser-sheet scanning systems with similar time response, which typically measure 10-20 planes.

Danehy, Paul M.↗

NASA NTRS2008

The X-43A Flush Airdata Sensing System Flight Test Results

The National Aeronautics and Space Administration (NASA) has flight-tested a flush airdata sensing (FADS) system on the Hyper-X Research Vehicle (X-43A) at hypersonic speeds during the course of two successful flights. For this series of tests, the FADS system was calibrated to operate between Mach 3 and Mach 8, and flight test data was collected between Mach 1 and Mach 10. The FADS system acquired pressure data from surface-mounted ports and generated a real-time angle-of-attack (alpha) estimate on board the X-43A. The collected data were primarily intended to evaluate the FADS system performance, and the estimated alpha was used by the flight control algorithms on the X-43A for only a portion of the first successful flight. This paper provides an overview of the FADS system and alpha estimation algorithms, presents the in-flight alpha estimation algorithm performance, and provides comparisons to wind tunnel results and theory. Results indicate that the FADS system adequately estimated the alpha of the vehicle during the hypersonic portions of the two flights.

Baumann, Ethan↗