Evaluation of CFD as a Surrogate for Wind-Tunnel Testing: Experimental Uncertainty Quantification for the UPWT Flow Survey Test
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Erin Hubbard↗
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Improving TCP Network Performance by Detecting and Reacting to Packet Reordering
There are many factors governing the performance of TCP-basec applications traversing satellite channels. The end-to-end performance of TCP is known to be degraded by the reordering, delay, noise and asymmetry inherent in geosynchronous systems. This result has been largely based on experiments that evaluate the performance of TCP in single flow tests. While single flow tests are useful for deriving information on the theoretical behavior of TCP and allow for easy diagnosis of problems they do not represent a broad range of realistic situations and therefore cannot be used to authoritatively comment on performance issues. The experiments discussed in this report test TCP s performance in a more dynamic environment with competing traffic flows from hundreds of TCP connections running simultaneously across the satellite channel. Another aspect we investigate is TCP's reaction to bit errors on satellite channels. TCP interprets loss as a sign of network congestion. This causes TCP to reduce its transmission rate leading to reduced performance when loss is due to corruption. We allowed the bit error rate on our satellite channel to vary widely and tested the performance of TCP as a function of these bit error rates. Our results show that the average performance of TCP on satellite channels is good even under conditions of loss as high as bit error rates of 10(exp -5)
Kruse, Hans↗
Vortex shedding flow meter performance at high flow velocities
In some of the ducts of the Space Shuttle Main Engine (SSME), the maximum liquid oxygen flow velocities approach 10 times those at which liquid flow measurements are normally made. The hydrogen gas flow velocities in other ducts exceed the maximum for gas flow measurement by more than a factor of 3. The results presented here show from water flow tests that vortex shedding flow meters of the appropriate design can measure water flow to velocities in excess of 55 m/s, which is a Reynolds number of about 2 million. Air flow tests have shown that the same meter can measure flow to a Reynolds number of at least 22 million. Vortex shedding meters were installed in two of the SSME ducts and tested with water flow. Narrow spectrum lines were obtained and the meter output frequencies were proportional to flow to + or - 0.5% or better over the test range with no flow conditioning, even though the ducts had multiple bends preceeding the meter location. Meters with the shedding elements only partially spanning the pipe and some meters with ring shaped shedding elements were also tested.
Siegwarth, J. D.↗
NASA Ares I Launch Vehicle First Stage Roll Control System Cold Flow Development Test Program Overview
The Ares I launch vehicle is the selected design, chosen to return humans to the moon, Mars, and beyond. It is configured in two inline stages: the First Stage is a Space Shuttle derived five-segment Solid Rocket Booster and the Upper Stage is powered by a Saturn V derived J-2X engine. During launch, roll control for the First Stage (FS) is handled by a dedicated Roll Control System (RoCS) located on the connecting Interstage. That system will provide the Ares I with the ability to counteract induced roll torque while any induced yaw or pitch moments are handled by vectoring of the booster nozzle. This paper provides an overview of NASA s Ares I FS RoCS cold flow development test program including detailed test objectives, types of tests run to meet those objectives, an overview of the results, and applicable lessons learned. The test article was built and tested at the NASA Marshall Space Flight Center in Huntsville, AL. The FS RoCS System Development Test Article (SDTA) is a full scale, flight representative water flow test article whose primary objective was to obtain fluid system performance data to evaluate integrated system level performance characteristics and verify analytical models. Development testing and model correlation was deemed necessary as there is little historical precedent for similar large flow, pulsing systems such as the FS RoCS. The cold flow development test program consisted of flight-similar tanks, pressure regulators, and thruster valves, as well as plumbing simulating flight geometries, combined with other facility grade components and structure. Orifices downstream of the thruster valves were used to simulate the pressure drop through the thrusters. Additional primary objectives of this test program were to: evaluate system surge pressure (waterhammer) characteristics due to thruster valve operation over a range of mission duty cycles at various feed system pressures, evaluate temperature transients and heat transfer in the pressurization system, including regulator blowdown and propellant ullage performance, measure system pressure drops for comparison to analysis of tubing and components, and validate system activation and re-activation procedures for the helium pressurant system. Secondary objectives included: validating system processes for loading, unloading, and purging, validating procedures and system response for multiple failure scenarios, including relief valve operation, and evaluating system performance for contingency scenarios. The test results of the cold flow development test program are essential in validating the performance and interaction of the Roll Control System and anchoring analysis tools and results to a Critical Design Review level of fidelity.
Butt, Adam↗
NCV Flow Diagnostic Test Results
There were two objectives for this test. First, was to assess the reasons why there is approximately 1.5 drag counts (cts) discrepancy between measured and computed drag improvement of the Non-linear Cruise Validation (NCV) over the Technology Concept Airplane (TCA) wing body (WB) configurations. The Navier-Stokes (N-S) pre-test predictions from Boeing Commercial Airplane Group (BCAG) show 4.5 drag cts of improvement for NCV over TCA at a lift coefficient (CL) of 0. I at Mach 2.4. The pre-test predictions from Boeing Phantom Works - Long Beach, BPW-LB, show 3.75 drag cts of improvement. BCAG used OVERFLOW and BPW-LB used CFL3D. The first test entry to validate the improvement was held at the NASA Langley Research Center (LARC) UPV;T, test number 1687. The experimental results showed that the drag improvement was only 2.6 cts, not accounting for laminar run and trip drag. This is approximately 1.5 cts less than predicted computationally. In addition to the low Reynolds Number (RN) test, there was a high RN test in the Boeing Supersonic Wind Tunnel (BSWT) of NCV and TCA. BSV@T test 647 showed that the drag improvement of NCV over TCA was also 2.6 cts, but this did account for laminar run and trip drag. Every effort needed to be done to assess if the improvement measured in LaRC UPWT and BSWT was correct. The second objective, once the first objective was met, was to assess the performance increment of NCV over TCA accounting for the associated laminar run and trip drag corrections in LaRC UPWT. We know that the configurations tested have laminar flow on portions of the wing and have trip drag due to the mechanisms used to force the flow to go from laminar to turbulent aft of the transition location.
Cappuccio, Mina↗
A Design Tool for Liquid Rocket Engine Injectors
A practical design tool for the analysis of flowfields near the injector face has been developed and used to analyze the Fastrac engine. The objective was to produce a computational design tool which was detailed enough to predict the interactive effects of injector element impingement angles and points and the momenta of the individual orifice flows. To obtain a model which could be used to simulate a significant number of individual orifices, a homogeneous computational fluid dynamics model was developed. To describe liquid and vapor sub- and super-critical flows, the model included thermal and caloric equations of state which were valid over a wide range of pressures and temperatures. A homogeneous model was constructed such that the local state of the flow was determined directly, i.e. the quality of the flow was calculated. Such a model does not identify drops or their distribution, but it does allow the flow along the injector face and into the acoustic cavity to be predicted. It also allows the film coolant flow to be accurately described. The initial evaluation of the injector code was made by simulating cold flow from an unlike injector element and from a like-on-like overlapping fan (LOL) injector element. The predicted mass flux distributions of these injector elements compared well to cold flow test results. These are the same cold flow tests which serve as the data base for the JANNAF performance prediction codes. The flux distributions 1 inch downstream of the injector face are very similar; the differences were somewhat larger at further distances from the faceplate. Since the cold flow testing did not achieve good mass balances when integrations across the entire fan were made, the CFD simulation appears to be reasonable alternative to future cold flow testing. To simulate the Fastrac, an RP-1/LOX combustion model must be chosen. This submodel must be relatively simple to accomplish three-dimensional, multiphase flow simulations. Single RP-1 pyrolysis and partial oxidation steps were chosen and the combustion was completed with the wet CO mechanism. Soot was also formed with a single global reaction. To validate the combustion submodel, global data from gas generator tests and from subscale motor test were used to predict qualitatively correct mean molecular weights, temperature, and soot levels. Because such tests do not provide general kinetics rates, the methodology is not necessarily appropriate for other than rocket type flows conditions. Soot predictions were made so that radiation heating to the motor walls can be made. These initial studies of the Fastrac were for a small region close to the injector face and chamber wall which included a segment of the acoustic cavity. The region analyzed includes 11 individual orifice holes to represent the LOL elements and the H2 film coolant holes. Typical results of this simulation are shown in Figure 1. At this point the only available test data to verify the predictions are temperatures measured in the acoustic cavity. These temperatures are in reasonable agreement at about 2000R (1111 K). Future work is expected to include improving the computational efficiency or the CFD model and/or using more computer capacity than the single Pentium PC with which these simulations were made.
Farmer, Richard C.↗
Performance and test section flow characteristics of the National Full-Scale Aerodynamics Complex 80- by 120-Foot Wind Tunnel
Results from the performance and test section flow calibration of the 80- by 120-Foot Wind Tunnel are presented. Measurements indicating the 80- by 120-ft test section flow quality were obtained throughout the tunnel operational envelope and for atmospheric wind speeds up to approximately 20 knots. Tunnel performance characteristics and a dynamic pressure system calibration were also documented during the process of mapping the test section flow field. Experimental results indicate that the test section flow quality is relatively insensitive to dynamic pressure and the level of atmospheric winds experienced during the calibration. The dynamic pressure variation in the test section is within +/-75 percent of the average. The axial turbulence intensity is less than 0.5 percent up to the maximum test section speed of 100 knots, and the vertical and lateral flow angle variations are within +/-5 deg and +/-7 deg, respectively. Atmospheric winds were found to affect the pressure distribution in the test section only at high ratios of wind speed to test section speed.
Zell, Peter T.↗
Development of braided fiber seals for engine applications
A new type of braided fiber seal was developed for high temperature engine applications. Development work performed includes seal design, fabrication, leakage flow testing, and flow resistance modeling. This new type of seal utilizes the high flow resistance of tightly packed fibers and the conformability of textile structures. The seal contains a core part with aligned fibers, and a sheath with braided fiber layers. Seal samples are made by using the conventional braiding process. Leakage flow measurements are then performed. Mass flow rate versus the simulated engine pressure and preload pressure is recorded. The flow resistance of the seal is analyzed using the Ergun equation for flow through porous media, including both laminar and turbulent effects. The two constants in the Ergun equation are evaluated for the seal structures. Leakage flow of the seal under the test condition is found to be in the transition flow region. The analysis is used to predict the leakage flow performance of the seal with the determined design parameters.
Cai, Zhong↗
VSTOL ground effects testing with flow visualization and image enhancement
A remotely controlled high-energy fiber-optic light delivery technique is employed to examine the implementation of a laser-light-sheet flow-visualization system. During testing, video data are enhanced in real time using digital image processing techniques. A summary of test results for an advanced VSTOL configuration in ground effect, and techniques for the generation of 3D reconstructions for the flowfield are outlined. The system performed well during all phases of the test and proved to be an extremely useful asset to the overall test program. The most useful application of the flow visualization system was the interactive real-time flow field analysis made during the actual testing.
Kegelman, Jerome T.↗
Testing and Performance Verification of a High Bypass Ratio Turbofan Rotor in an Internal Flow Component Test Facility
A 1/5 scale model rotor representative of a current technology, high bypass ratio, turbofan engine was installed and tested in the W8 single-stage, high-speed, compressor test facility at NASA Glenn Research Center (GRC). The same fan rotor was tested previously in the GRC 9x15 Low Speed Wind Tunnel as a fan module consisting of the rotor and outlet guide vanes mounted in a flight-like nacelle. The W8 test verified that the aerodynamic performance and detailed flow field of the rotor as installed in W8 were representative of the wind tunnel fan module installation. Modifications to W8 were necessary to ensure that this internal flow facility would have a flow field at the test package that is representative of flow conditions in the wind tunnel installation. Inlet flow conditioning was designed and installed in W8 to lower the fan face turbulence intensity to less than 1.0 percent in order to better match the wind tunnel operating environment. Also, inlet bleed was added to thin the casing boundary layer to be more representative of a flight nacelle boundary layer. On the 100 percent speed operating line the fan pressure rise and mass flow rate agreed with the wind tunnel data to within 1 percent. Detailed hot film surveys of the inlet flow, inlet boundary layer and fan exit flow were compared to results from the wind tunnel. The effect of inlet casing boundary layer thickness on fan performance was quantified. Challenges and lessons learned from testing this high flow, low static pressure rise fan in an internal flow facility are discussed.
VanZante, Dale E.↗
Waterhammer Modeling for the Ares I Upper Stage Reaction Control System Cold Flow Development Test Article
The Upper Stage Reaction Control System provides three-axis attitude control for the Ares I launch vehicle during active Upper Stage flight. The system design must accommodate rapid thruster firing to maintain the proper launch trajectory and thus allow for the possibility to pulse multiple thrusters simultaneously. Rapid thruster valve closure creates an increase in static pressure, known as waterhammer, which propagates throughout the propellant system at pressures exceeding nominal design values. A series of development tests conducted in the fall of 2009 at Marshall Space Flight Center were performed using a water-flow test article to better understand fluid performance characteristics of the Upper Stage Reaction Control System. A subset of the tests examined waterhammer along with the subsequent pressure and frequency response in the flight-representative system and provided data to anchor numerical models. This thesis presents a comparison of waterhammer test results with numerical model and analytical results. An overview of the flight system, test article, modeling and analysis are also provided.
Williams, Jonathan H.↗
Operational experience in the Langley expansion tube with various test gases
A resume' of operating experiences with the Langley Expansion Tube is presented. The driver gas was unheated helium at a nominal pressure of 5000 psi and the majority of the data presented are for air and carbon dioxide test gases. The primary purpose of these data is to illustrate the effects of various parameters on quasi-steady test flow duration, as well as free stream and post-normal shock flow conditions. The discussion shows that the Langley Expansion Tube is an operational facility capable of producing good quality, highly repeatable, quasi-steady flow for test times sufficient to establish flow about blunt axisymmetric and two-dimensional models.
Miller, C. G.↗
Optical Air Flow Measurements for Flight Tests and Flight Testing Optical Air Flow Meters
Optical air flow measurements can support the testing of aircraft and can be instrumental to in-flight investigations of the atmosphere or atmospheric phenomena. Furthermore, optical air flow meters potentially contribute as avionics systems to flight safety and as air data systems. The qualification of these instruments for the flight environment is where we encounter the systems in flight testing. An overview is presented of different optical air flow measurement techniques applied in flight and what can be achieved with the techniques for flight test purposes is reviewed. All in-flight optical airflow velocity measurements use light scattering. Light is scattered on both air molecules and aerosols entrained in the air. Basic principles of making optical measurements in flight, some basic optical concepts, electronic concepts, optoelectronic interfaces, and some atmospheric processes associated with natural aerosols are reviewed. Safety aspects in applying the technique are shortly addressed. The different applications of the technique are listed and some typical examples are presented. Recently NASA acquired new data on mountain rotors, mountain induced turbulence, with the ACLAIM system. Rotor position was identified using the lidar system and the potentially hazardous air flow profile was monitored by the ACLAIM system.
Jentink, Henk W.↗
SSME hot gas manifold flow comparison test
An account is given of the High Pressure Fuel Turbopump (HPFT) component of NASA's Alternate Turbopump Development effort, which is aimed at the proper aerodynamic integration of the current Phase II three-duct SSME Hot Gas Manifold (HGM) and the future 'Phase II-plus' two-duct HGM. Half-scale water flow tests of both HGM geometries were conducted to provide initial design data for the HPFT. The results reveal flowfield results and furnish insight into the performance differences between the two HGM flowpaths. Proper design of the HPFT can potentially secure significant flow improvements in either HGM configuration.
Cox, G. B., Jr.↗
Launch Vehicle Sizing Benefits Utilizing Main Propulsion System Crossfeed and Project Status
To meet the goals for a next generation Reusable Launch Vehicle (RLV), a unique propulsion feed system concept was identified using crossfeed between the booster and orbiter stages that could reduce the Two-Stage-to-Orbit (TSTO) vehicle weight and Design, Development, Test and Evaluation (DDT&E) costs by approximately 25%, while increasing safety and reliability. The Main Propulsion System (MPS) crossfeed water demonstration test program addresses all activities required to reduce the risks for the MPS crossfeed system from a Technology Readiness Level (TRL) of 2 to 4 by the completion of testing and analysis by June 2003. During the initial period, that ended in March 2002, a subscale water flow test article was defined. Procurement of a subscale crossfeed check valve was initiated and the specifications for the various components were developed. The fluid transient and pressurization analytical models were developed separately and successfully integrated. The test matrix for the water flow test was developed to correlate the integrated model. A computational fluid dynamics (CFD) model of the crossfeed check valve was developed to assess flow disturbances and internal flow dynamics. Based on the results, the passive crossfeed system concept was very feasible and offered a safe system to be used in an RLV architecture. A water flow test article was designed to accommodate a wide range of flows simulating a number of different types of propellant systems. During the follow-on period, the crossfeed system model will be further refined, the test article will be completed, the water flow test will be performed, and finally the crossfeed system model will be correlated with the test data. This validated computer model will be used to predict the full-scale vehicle crossfeed system performance.
Chandler, Frank↗
Cold Flow Propulsion Test Complex Pulse Testing
When the propellants in a liquid rocket engine burn, the rocket not only launches and moves in space, it causes forces that interact with the vehicle itself. When these interactions occur under specific conditions, the vehicle's structures and components can become unstable. One instability of primary concern is termed pogo (named after the movement of a pogo stick), in which the oscillations (cycling movements) cause large loads, or pressure, against the vehicle, tanks, feedlines, and engine. Marshall Space Flight Center (MSFC) has developed a unique test technology to understand and quantify the complex fluid movements and forces in a liquid rocket engine that contribute strongly to both engine and integrated vehicle performance and stability. This new test technology was established in the MSFC Cold Flow Propulsion Test Complex to allow injection and measurement of scaled propellant flows and measurement of the resulting forces at multiple locations throughout the engine.
McDougal, Kris↗
Oscillating-Flow Regenerator Test Rig: Hardware and Theory With Derived Correlations for Screens and Felts
A number of wire mesh and metal felt test samples, with a range of porosities, yield generic correlations for friction factor, Nusselt number, enhanced axial conduction ratio, and overall heat flux ratio. This information is directed primarily toward stirling cycle regenerator modelers, but will be of use to anyone seeking to better model fluid flow through these porous materials. Behind these results lies an oscillating-flow test rig, which measures pumping dissipation and thermal energy transport in sample matrices, and several stages of data-reduction software, which correlate instantaneous values for the above dimensionless groups. Within the software, theoretical model reduces instantaneous quantifies from cycle-averaged measurables using standard parameter estimation techniques.
Gedeon, D.↗
Results of oil flow visualization tests of an 0.010-scale model (52-OT) of the space shuttle orbiter-tank mated and orbiter configurations in the AEDC VKF tunnel B (IA17B)
An 0.010-scale model of the space shuttle (orbiter-tank mated and orbiter configurations) was tested in the AEDC VKF Tunnel B to investigate aerodynamic flow patterns. The tests utilized oil flow techniques to visualize the flow patterns. Tunnel free stream Mach number was 7.95 and nominal unit Reynolds number was 3.7 million per foot. Model angle of attack was varied from -5 deg through 10 deg and angle of sideslip was 0 deg and 2 deg. Photographs of resulting oil flow patterns are presented.
Daileda, J. J.↗