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DOE OSTI2018

Principles of aerosol jet printing

Aerosol jet printing (AJP) has emerged as a promising method for microscale digital additive manufacturing using functional nanomaterial inks. While compelling capabilities have been demonstrated in the research community in recent years, the development and refinement of inks and process parameters largely follows empirical observations, with an extensive phase space over which to optimize. While this has led to general qualitative guidelines and ink- and machine-specific correlations, a more fundamental understanding based on principles of aerosol physics and fluid mechanics is lacking. This contrasts with more mature printing technologies, for which foundational physical principles have been rigorously examined. Presented here is a broad framework for describing the AJP process. Simple analytical models are employed to ensure generality and accessibility of the results, while experimental validation using a silver nanoparticle ink supports the physical relevance of the approach. In conclusion, this basic understanding enables a description of process limitations grounded in fundamental principles, as well as guidelines for improved printer design, ink formulation, and print parameter optimization.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

NASA NTRS1986

Design and evaluation of a failure detection and isolation algorithm for restructurable control systems

The use of a decentralized approach to failure detection and isolation for use in restructurable control systems is examined. This work has produced: (1) A method for evaluating fundamental limits to FDI performance; (2) Application using flight recorded data; (3) A working control element FDI system with maximal sensitivity to critical control element failures; (4) Extensive testing on realistic simulations; and (5) A detailed design methodology involving parameter optimization (with respect to model uncertainties) and sensitivity analyses. This project has concentrated on detection and isolation of generic control element failures since these failures frequently lead to emergency conditions and since knowledge of remaining control authority is essential for control system redesign. The failures are generic in the sense that no temporal failure signature information was assumed. Thus, various forms of functional failures are treated in a unified fashion. Such a treatment results in a robust FDI system (i.e., one that covers all failure modes) but sacrifices some performance when detailed failure signature information is known, useful, and employed properly. It was assumed throughout that all sensors are validated (i.e., contain only in-spec errors) and that only the first failure of a single control element needs to be detected and isolated. The FDI system which has been developed will handle a class of multiple failures.

Weiss, Jerold L.↗

NASA NTRS2011

Hybrid CFD/CAA Modeling for Liftoff Acoustic Predictions

This paper presents development efforts at the NASA Marshall Space flight Center to establish a hybrid Computational Fluid Dynamics and Computational Aero-Acoustics (CFD/CAA) simulation system for launch vehicle liftoff acoustics environment analysis. Acoustic prediction engineering tools based on empirical jet acoustic strength and directivity models or scaled historical measurements are of limited value in efforts to proactively design and optimize launch vehicles and launch facility configurations for liftoff acoustics. CFD based modeling approaches are now able to capture the important details of vehicle specific plume flow environment, identifY the noise generation sources, and allow assessment of the influence of launch pad geometric details and sound mitigation measures such as water injection. However, CFD methodologies are numerically too dissipative to accurately capture the propagation of the acoustic waves in the large CFD models. The hybrid CFD/CAA approach combines the high-fidelity CFD analysis capable of identifYing the acoustic sources with a fast and efficient Boundary Element Method (BEM) that accurately propagates the acoustic field from the source locations. The BEM approach was chosen for its ability to properly account for reflections and scattering of acoustic waves from launch pad structures. The paper will present an overview of the technology components of the CFD/CAA framework and discuss plans for demonstration and validation against test data.

Strutzenberg, Louise L.↗

DOE OSTI2023

Plutonium Age Dating Interlaboratory Comparison Overview - Project Design, Sample Preparation, and Results [Slides]

Project Design – How do you validate measured Pu model age? There are no certified reference materials (CRMs) that are certified for Pu model age or purification dates. There are no Am isotopic CRMs - IRMM 0243 243 Am spike has 241 Am impurity that can be used; Community working toward "consensus ages." This project executed and evaluated results from a Pu age dating interlaboratory comparison with six IAEA NWAL participant laboratories. It also ran the first quality control evaluation of single-picogram to sub-picogram scale interlaboratory 241 Am assay measurements from cotton swipe matrices. Results are promising, with a majority of 241 Am/ 241 Pu model age results agree to within 1 to 4 years. The calculated 241 Am assay results show interlaboratory variability, expanded percent uncertainties on calculated consensus 241 Am concentrations were: PuAge-S1 = 3.1 %, PuAge-S2 = 23 %, and PuAge-S3 = 26 %. Data can be used to investigate laboratory methods and improve precision and accuracy of 241 Pu and 241 Am assay for future campaigns.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS2000

Implications of Simulation Conceptual Model Development for Simulation Management and Uncertainty Assessment

A simulation conceptual model is a simulation developers way of translating modeling requirements (i. e., what is to be represented by the simulation or its modification) into a detailed design framework (i. e., how it is to be done), from which the software, hardware, networks (in the case of distributed simulation), and systems/equipment that will make up the simulation can be built or modified. A conceptual model is the collection of information which describes a simulation developers concept about the simulation and its pieces. That information consists of assumptions, algorithms, characteristics, relationships, and data. Taken together, these describe how the simulation developer understands what is to be represented by the simulation (entities, actions, tasks, processes, interactions, etc.) and how that representation will satisfy the requirements to which the simulation responds. Thus the conceptual model is the basis for judgment about simulation fidelity and validity for any condition that is not specifically tested. The more perspicuous and precise the conceptual model, the more likely it is that the simulation development will both fully satisfy requirements and allow demonstration that the requirements are satisfied (i. e., validation). Methods used in simulation conceptual model development have significant implications for simulation management and for assessment of simulation uncertainty. This paper suggests how to develop and document a simulation conceptual model so that the simulation fidelity and validity can be most effectively determined. These ideas for conceptual model development apply to all simulation varieties. The paper relates these ideas to uncertainty assessments as they relate to simulation fidelity and validity. The paper also explores implications for simulation management from conceptual model development methods, especially relative to reuse of simulation components.

Pace, Dale K.↗

DOE OSTI2019

A Comparative Study of the Efficacy of Local/Global and Parametric/Nonparametric Machine Learning Methods for Establishing Structure–Property Linkages in High-Contrast 3D Elastic Composites

Reduced-order structure–property (S-P) linkages play a pivotal role in the tailored design of materials for advanced engineering components. There is a critical need to distill these from the simulation datasets aggregated using sophisticated, computationally expensive, physics-based numerical tools (e.g., finite element methods). The recent emergence of materials data science approaches has opened new avenues for addressing this challenge. In this paper, we critically compare the relative merits of the application of four distinct machine learning approaches for their efficacy in extracting microstructure-property linkages from the finite element simulation data aggregated on high-contrast elastic composites with different microstructures. The machine learning approaches selected for the study have included different combinations of local/global and parametric/nonparametric approaches. Furthermore, the nonparametric approaches selected for this study are based on Gaussian Process (GP) models that allow for a formal treatment of uncertainty quantification in the predicted values. The predictive performances of these different approaches have been compared against each other using rigorous cross-validation error metrics. Furthermore, their sensitivity to both the dataset size and dimensionality has been investigated.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Crystal structure, energetics, and phase stability of strengthening precipitates in Mg alloys: A first-principles study

Magnesium alloys have attracted increasing interest due to their potential use as light-weight structural materials but their application is limited by their low strength compared to conventional alloys. Age hardening is commonly employed to form strengthening precipitates in such alloys, which impedes the motion of dislocations, and leads to improved strength. However, the exact composition, crystal structure, and energetics of many of these strengthening precipitates are either unknown or not clearly resolved, making the precise engineering and design of such alloys difficult. Toward this end, we use first-principles density functional theory calculations to elucidate the crystal structures and energetics of a very large set of precipitates in magnesium alloys. For cases where the precipitate crystal structure is not known, we comprehensively search over decorations of many prototype structures, including hcp superstructures, and in addition, perform global structural optimization using the Minima Hopping Method to predict suitable crystal structures. For all the strengthening precipitates, we calculate the formation energies, construct the respective zero temperature convex hulls, and analyze their stabilities. Here, we show that the bulk formation energies per solute atom (essentially, the solute chemical potentials) decrease along the observed sequences of precipitation, validating our calculations in Mg-{Nd, Gd, Y, Y-Nd, Nd-Zn, Gd-Zn, Y-Zn, Al, Zn, Sn, Al-Ca, Ca-Zn} alloy systems. In addition, we construct a monolayer model for the Guinier-Preston zones (GP zones) observed in the Mg-Nd-Zn system during early stages of age hardening, and thereby explain the formation of the γ" (Mg 5 (Nd,Zn)) phase from the GP zones, as observed in experiments.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Automated Clean Chemistry for Bulk Analysis of Environmental Swipe Samples – Final Report

Sample preparation methods for mass spectrometry are being automated using commercial-off-the-shelf (COTS) equipment to shorten lengthy and costly manual chemical purification procedures. This development addresses a serious need in the International Atomic Energy Agency’s (IAEA) Network of Analytical Laboratories (NWAL) to increase efficiency in the Bulk Analysis of Environmental Samples for Safeguards program with a method that allows unattended, overnight operation. In collaboration with Elemental Scientific Inc. (ESI), the prepFAST-MC2 was designed based on COTS equipment. It was modified for uranium/plutonium separations using renewable columns packed with Eichrom TEVA® and UTEVA® resins, with a chemical separation method based on the Oak Ridge National Laboratory (ORNL) NWAL chemical procedure. Initial verification of individual columns yielded small elution volumes with consistent elution profiles and good recovery. Combined column calibration demonstrated ample separation without crosscontamination of the eluent. Automated packing and unpacking of the built-in columns initially showed >15% deviation in resin loading by weight, which can lead to inconsistent separations. Optimization of the packing and unpacking methods led to a reduction in the variability of the packed resin to less than 5% daily. Based on the initial experience at ORNL with the prepFAST-MC2, a second-generation model, the prepFAST-SR, was built by ESI. The newly designed prepFAST-SR has several upgrades compared with the original prepFAST-MC2. The upgrades largely addressed issues with the reliability of unpacking the Eichrom columns and with ventilation to ensure adequate removal of acid vapors. Both systems are currently installed in the Ultra-Trace Forensics Science Center at ORNL. Separations of mixed uranium and plutonium samples containing certified reference materials were analyzed by multi-collector inductively coupled plasma mass spectrometry and yielded good results. Current efforts have demonstrated a wider applicability of the prepFAST system. Near-quantitative removal of metal interferences was achieved with the system in both uranium and plutonium separated fractions. Successful system validation was completed with several archived samples. Isotopic results from archived samples and certified reference materials were well within data quality limits for the IAEA NWAL. Additional COTS equipment has been evaluated for its potential to aid the prepFAST-SR system in reducing the time allotments and cleanroom infrastructure requirements for accurate separations. Overall, these efforts help ensure continued efficient and effective operation of the NWAL. Comparison of the amount of personnel time necessary for successful manual vs. automated chemical separations showed a significant decrease in hands-on time from 9.8 hours to 35 minutes for seven samples, respectively. This documented time savings and reduced labor translates to a significant cost savings per sample. Overall, the system will enable faster sample reporting times at reduced cost by limiting personnel hours dedicated to the chemical separation.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS2007

Bayesian Analysis of the Cosmic Microwave Background

There is a wealth of cosmological information encoded in the spatial power spectrum of temperature anisotropies of the cosmic microwave background! Experiments designed to map the microwave sky are returning a flood of data (time streams of instrument response as a beam is swept over the sky) at several different frequencies (from 30 to 900 GHz), all with different resolutions and noise properties. The resulting analysis challenge is to estimate, and quantify our uncertainty in, the spatial power spectrum of the cosmic microwave background given the complexities of "missing data", foreground emission, and complicated instrumental noise. Bayesian formulation of this problem allows consistent treatment of many complexities including complicated instrumental noise and foregrounds, and can be numerically implemented with Gibbs sampling. Gibbs sampling has now been validated as an efficient, statistically exact, and practically useful method for low-resolution (as demonstrated on WMAP 1 and 3 year temperature and polarization data). Continuing development for Planck - the goal is to exploit the unique capabilities of Gibbs sampling to directly propagate uncertainties in both foreground and instrument models to total uncertainty in cosmological parameters.

methods - statistical↗

NASA NTRS2019

2040 Vision Study: an Enlargement of Model Based Engineering

Over the last few decades, advances in high-performance computing, new materials characterization methods, and, more recently, an emphasis on integrated computational materials engineering (ICME) and additive manufacturing have been a catalyst for multiscale modeling and simulation-based design of materials and structures in the aerospace industry. As a result, NASA's Transformational Tools and Technology (TTT) Project sponsored a study (performed by a team led by Pratt & Whitney) to define the potential 25-year future state required for integrated multiscale modeling of materials and systems (e.g., load-bearing structures) to accelerate the pace and reduce the expense of innovation in future aerospace and aeronautical systems. This talk will briefly review the findings of this 2040 Vision study (e.g., the 2040 vision state; the required interdependent core technical work areas, Key Element (KE); associated critical gaps and actions to close those gaps; and major recommendations). The study, NASA CR 2018- 219771, envisions the development of a cyber-physical-social ecosystem comprised of experimentally verified and validated computational models, tools, and techniques, along with the associated digital tapestry, that marries two non-mutually exclusive paradigms _ "design of the materials" (material scientist viewpoint) and "design with the materials" (structural analyst viewpoint) _ into a concurrent transformational paradigm that impacts the entire supply chain to enable cost-effective, rapid, and revolutionary design of fit-for-purpose materials, components, and systems. Although the vision focused on aeronautics and space applications, it is believed that other engineering communities (e.g., automotive, biomedical, etc.) can benefit as well from the proposed framework with only minor modifications. Finally, it is TTT's hope and desire that this vision provides the strategic guidance to both public and private research and development decision makers to make the proposed 2040 vision state a reality and thereby provide a significant advancement in the United States global competitiveness.

Arnold, Steven M.↗

NASA NTRS1982

Analytical solution for the drift behavior of Dynamics Explorer-B

The Dynamics Explorer (DE) mission was designed to explore the earth's magnetosphere, ionosphere, and plasmasphere. The DE mission employs two spacecraft, including DE-A and DE-B. The spacecraft were launched from the Western Test Range on Aug. 3, 1981, onboard the same Delta launch vehicle. The two spacecraft were placed in a coplanar polar orbit, with DE-A in a high altitude orbit (perigee = 570 km and apogee = 23174 km) and DE-B in a low altitude orbit (perigee = 309 km and apogee = 1013 km). In the present investigation, an attempt has been made to validate the flight data for DE-B with analytic and simulation results. The external torques acting on the spacecraft are represented in terms of tractable mathematical functions. A piecewise linear model of the superrotation of the upper atmosphere is assumed. The effect of individual torques on the long-term pitch axis motion is investigated using analytic and simulation methods. The results are found to be in very good agreement with the available flight data.

Sellappan, R. G.↗

NASA NTRS1995

Development of a two-equation turbulence model for hypersonic flows: Evaluation of a low Reynolds number correction to the Kappa - epsilon two equation compressible turbulence model - Volume 1

The objective of the current research is the development of an improved k-epsilon two-equation compressible turbulence model for turbulent boundary layer flows experiencing strong viscous-inviscid interactions. The development of an improved model is important in the design of hypersonic vehicles such as the National Aerospace Plane (NASP) and the High Speed Civil Transport (HSCT). Improvements have been made to the low Reynolds number functions in the eddy viscosity and dissipation of solenoidal dissipation of the k-epsilon turbulence mode. These corrections offer easily applicable modifications that may be utilized for more complex geometries. The low Reynolds number corrections are functions of the turbulent Reynolds number and are therefore independent of the coordinate system. The proposed model offers advantages over some current models which are based upon the physical distance from the wall, that modify the constants of the standard model, or that make more corrections than are necessary to the governing equations. The code has been developed to solve the Favre averaged, boundary layer equations for mass, momentum, energy, turbulence kinetic energy, and dissipation of solenoidal dissipation using Keller's box scheme and the Newton spatial marching method. The code has been validated by removing the turbulent terms and comparing the solution with the Blasius solution, and by comparing the turbulent solution with an existing k-epsilon model code using wall function boundary conditions. Excellent agreement is seen between the computed solution and the Blasius solution, and between the two codes. The model has been tested for both subsonic and supersonic flat-plate turbulent boundary layer flow by comparing the computed skin friction with the Van Driest II theory and the experimental data of Weighardt; by comparing the transformed velocity profile with the data of Weighardt, and the Law of the Wall and the Law of the Wake; and by comparing the computed results of an adverse pressure gradient with the experimental data of Fernando and Smits. Good agreement is obtained with the experimental correlations for all flow conditions.

Knight, Doyle D.↗

NASA NTRSDate not supplied

Characterization of Slosh Damping for Ortho-Grid and Iso-Grid Internal Tank Structures

Grid stiffened tank structures such as Ortho-Grid and Iso-Grid are widely used in cryogenic tanks for providing stiffening to the tank while reducing mass, compared to tank walls of constant cross-section. If the structure is internal to the tank, it will positively affect the fluid dynamic behavior of the liquid propellant, in regard to fluid slosh damping. As NASA and commercial companies endeavor to explore the solar system, vehicles will by necessity become more mass efficient, and design margin will be reduced where possible. Therefore, if the damping characteristics of the Ortho-Grid and Iso-Grid structure is understood, their positive damping effect can be taken into account in the systems design process. Historically, damping by internal structures has been characterized by rules of thumb and for Ortho-Grid, empirical design tools intended for slosh baffles of much larger cross-section have been used. There is little or no information available to characterize the slosh behavior of Iso-Grid internal structure. Therefore, to take advantage of these structures for their positive damping effects, there is much need for obtaining additional data and tools to characterize them. Recently, the NASA Marshall Space Flight Center conducted both sub-scale testing and computational fluid dynamics (CFD) simulations of slosh damping for Ortho-Grid and Iso-Grid tanks for cylindrical tanks containing water. Enhanced grid meshing techniques were applied to the geometrically detailed and complex Ortho-Grid and Iso-Grid structures. The Loci-STREAM CFD program with the Volume of Fluid Method module for tracking and locating the water-air fluid interface was used to conduct the simulations. The CFD simulations were validated with the test data and new empirical models for predicting damping and frequency of Ortho-Grid and Iso-Grid structures were generated.

Douglas G. Westra↗

DOE OSTI2019

Localized corrosion behavior of a single-phase non-equimolar high entropy alloy

In another work, a design method combining computational modeling and empirical knowledge has been reported to establish a more efficient paradigm for developing future corrosion resistant alloys. Using this approach, a single-phase non-equimolar high entropy alloy (HEA) was successfully designed and synthesized. In this work, a detailed experimental investigation of the localized corrosion behavior of this alloy is presented. The HEA was found to possess superior intrinsic pitting resistance and exhibit strong passivity, even in 6 M HCl. The ability of this HEA to initiate and propagate a pit has been studied. The pitting resistance was shown to result from the formation of a passive film with exceedingly strong resistance to breakdown and from a high resistance to pit propagation. Pitting was discovered to be significantly inhibited because of the extremely strong passivity, even in solutions with lower pH and higher chloride concentration than found in a typical local pit environment. The outstanding properties of the HEA validate the approach used for designing corrosion-resistant HEAs.

36 MATERIALS SCIENCE↗

NASA NTRS2004

Reduced-Order Blade Mistuning Analysis Techniques Developed for the Robust Design of Engine Rotors

The primary objective of this research program is to develop vibration analysis tools, design tools, and design strategies to significantly improve the safety and robustness of turbine engine rotors. Bladed disks in turbine engines always feature small, random blade-to-blade differences, or mistuning. Mistuning can lead to a dramatic increase in blade forced-response amplitudes and stresses. Ultimately, this results in high-cycle fatigue, which is a major safety and cost concern. In this research program, the necessary steps will be taken to transform a state-of-the-art vibration analysis tool, the Turbo-Reduce forced-response prediction code, into an effective design tool by enhancing and extending the underlying modeling and analysis methods. Furthermore, novel techniques will be developed to assess the safety of a given design. In particular, a procedure will be established for using eigenfrequency curve veerings to identify "danger zones" in the operating conditions--ranges of rotational speeds and engine orders in which there is a great risk that the rotor blades will suffer high stresses. This work also will aid statistical studies of the forced response by reducing the necessary number of simulations. Finally, new strategies for improving the design of rotors will be pursued. Several methods will be investigated, including the use of intentional mistuning patterns to mitigate the harmful effects of random mistuning, and the modification of disk stiffness to avoid reaching critical values of interblade coupling in the desired operating range. Recent research progress is summarized in the following paragraphs. First, significant progress was made in the development of the component mode mistuning (CMM) and static mode compensation (SMC) methods for reduced-order modeling of mistuned bladed disks (see the following figure). The CMM method has been formalized and extended to allow a general treatment of mistuning. In addition, CMM allows individual mode mistuning, which accounts for the realistic effects of local variations in blade properties that lead to different mistuning values for different mode types (e.g., mistuning of the first torsion mode versus the second flexural mode). The accuracy and efficiency of the CMM method and the corresponding Turbo-Reduce code were validated for an example finite element model of a bladed disk.

Min, James B.↗

NASA NTRS2011

Core Noise - Increasing Importance

This presentation is a technical summary of and outlook for NASA-internal and NASA-sponsored external research on core (combustor and turbine) noise funded by the Fundamental Aeronautics Program Subsonic Fixed Wing (SFW) Project. Sections of the presentation cover: the SFW system-level noise metrics for the 2015, 2020, and 2025 timeframes; turbofan design trends and their aeroacoustic implications; the emerging importance of core noise and its relevance to the SFW Reduced-Perceived-Noise Technical Challenge; and the current research activities in the core-noise area, with additional details given about the development of a high-fidelity combustor-noise prediction capability as well as activities supporting the development of improved reduced-order, physics-based models for combustor-noise prediction. The need for benchmark data for validation of high-fidelity and modeling work and the value of a potential future diagnostic facility for testing of core-noise-reduction concepts are indicated. The NASA Fundamental Aeronautics Program has the principal objective of overcoming today's national challenges in air transportation. The SFW Reduced-Perceived-Noise Technical Challenge aims to develop concepts and technologies to dramatically reduce the perceived aircraft noise outside of airport boundaries. This reduction of aircraft noise is critical to enabling the anticipated large increase in future air traffic. Noise generated in the jet engine core, by sources such as the compressor, combustor, and turbine, can be a significant contribution to the overall noise signature at low-power conditions, typical of approach flight. At high engine power during takeoff, jet and fan noise have traditionally dominated over core noise. However, current design trends and expected technological advances in engine-cycle design as well as noise-reduction methods are likely to reduce non-core noise even at engine-power points higher than approach. In addition, future low-emission combustor designs could increase the combustion-noise component. The trend towards high-power-density cores also means that the noise generated in the low-pressure turbine will likely increase. Consequently, the combined result from these emerging changes will be to elevate the overall importance of turbomachinery core noise, which will need to be addressed in order to meet future noise goals.

Hultgren, Lennart S.↗

DOE OSTI2017

Coupling Visualization, Simulation, and Deep Learning for Ensemble Steering of Complex Energy Models: Preprint

We have developed a framework for the exploration, design, and planning of energy systems that combines interactive visualization with machine-learning based approximations of simulations through a general purpose dataflow API. Our system provides a visual inter- face allowing users to explore an ensemble of energy simulations representing a subset of the complex input parameter space, and spawn new simulations to 'fill in' input regions corresponding to new enegery system scenarios. Unfortunately, many energy simula- tions are far too slow to provide interactive responses. To support interactive feedback, we are developing reduced-form models via machine learning techniques, which provide statistically sound esti- mates of the full simulations at a fraction of the computational cost and which are used as proxies for the full-form models. Fast com- putation and an agile dataflow enhance the engagement with energy simulations, and allow researchers to better allocate computational resources to capture informative relationships within the system and provide a low-cost method for validating and quality-checking large-scale modeling efforts.

97 MATHEMATICS AND COMPUTING↗

NASA NTRS2015

Validation of 3-D Ice Accretion Measurement Methodology for Experimental Aerodynamic Simulation

Determining the adverse aerodynamic effects due to ice accretion often relies on dry-air wind-tunnel testing of artificial, or simulated, ice shapes. Recent developments in ice-accretion documentation methods have yielded a laser-scanning capability that can measure highly three-dimensional (3-D) features of ice accreted in icing wind tunnels. The objective of this paper was to evaluate the aerodynamic accuracy of ice-accretion simulations generated from laser-scan data. Ice-accretion tests were conducted in the NASA Icing Research Tunnel using an 18-in. chord, two-dimensional (2-D) straight wing with NACA 23012 airfoil section. For six ice-accretion cases, a 3-D laser scan was performed to document the ice geometry prior to the molding process. Aerodynamic performance testing was conducted at the University of Illinois low-speed wind tunnel at a Reynolds number of 1.8 × 10(exp 6) and a Mach number of 0.18 with an 18-in. chord NACA 23012 airfoil model that was designed to accommodate the artificial ice shapes. The ice-accretion molds were used to fabricate one set of artificial ice shapes from polyurethane castings. The laser-scan data were used to fabricate another set of artificial ice shapes using rapid prototype manufacturing such as stereolithography. The iced-airfoil results with both sets of artificial ice shapes were compared to evaluate the aerodynamic simulation accuracy of the laser-scan data. For five of the six ice-accretion cases, there was excellent agreement in the iced-airfoil aerodynamic performance between the casting and laser-scan based simulations. For example, typical differences in iced-airfoil maximum lift coefficient were less than 3 percent with corresponding differences in stall angle of approximately 1 deg or less. The aerodynamic simulation accuracy reported in this paper has demonstrated the combined accuracy of the laser-scan and rapid-prototype manufacturing approach to simulating ice accretion for a NACA 23012 airfoil. For several of the ice-accretion cases tested, the aerodynamics is known to depend upon the small, three-dimensional features of the ice. These data show that the laser-scan and rapid-prototype manufacturing approach is capable of replicating these ice features within the reported accuracies of the laser-scan measurement and rapid-prototyping method; thus providing a new capability for high-fidelity ice-accretion documentation and artificial ice-shape fabrication for icing research.

Aircraft Icing↗