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NASA NTRS2016

Wind Tunnel Interference Effects on Tilt Rotor Testing Using Computational Fluid Dynamics

Experimental techniques to measure rotorcraft aerodynamic performance are widely used. However, most of them are either unable to capture interference effects from bodies, or require an extremely large computational budget. The objective of the present research is to develop an XV-15 Tiltrotor Research Aircraft rotor model for investigation of wind tunnel wall interference using a novel Computational Fluid Dynamics (CFD) solver for rotorcraft, RotCFD. In RotCFD, a mid-fidelity Unsteady Reynolds Averaged Navier-Stokes (URANS) solver is used with an incompressible flow model and a realizable k-ε turbulence model. The rotor is, however, not modeled using a computationally expensive, unsteady viscous body-fitted grid, but is instead modeled using a blade-element model (BEM) with a momentum source approach. Various flight modes of the XV-15 isolated rotor, including hover, tilt, and airplane mode, have been simulated and correlated to existing experimental and theoretical data. The rotor model is subsequently used for wind tunnel wall interference simulations in the National Full-Scale Aerodynamics Complex (NFAC) at Ames Research Center in California. The results from the validation of the isolated rotor performance showed good correlation with experimental and theoretical data. The results were on par with known theoretical analyses. In RotCFD the setup, grid generation, and running of cases is faster than many CFD codes, which makes it a useful engineering tool. Performance predictions need not be as accurate as high-fidelity CFD codes, as long as wall effects can be properly simulated. For both test sections of the NFAC wall, interference was examined by simulating the XV-15 rotor in the test section of the wind tunnel and with an identical grid but extended boundaries in free field. Both cases were also examined with an isolated rotor or with the rotor mounted on the modeled geometry of the Tiltrotor Test Rig (TTR). A "quasi linear trim" was used to trim the thrust for the rotor to compare the power as a unique variable. Power differences between free field and wind tunnel cases were found from -7 to 0 percent in the 80- by 120-Foot Wind Tunnel and -1.6 to 4.8 percent in the 40- by 80-Foot Wind Tunnel, depending on the TTR orientation, tunnel velocity, and blade setting. The TTR will be used in 2016 to test the Bell 609 rotor in a similar fashion to the research in this report.

CFD↗
NASA NTRS2017

Navier-Stokes Simulation of UH-60A Rotor/Wake Interaction Using Adaptive Mesh Refinement

High-resolution simulations of rotor/vortex-wake interaction for a UH60-A rotor under BVI and dynamic stallconditions were carried out with the OVERFLOW Navier-Stokes code.a. The normal force and pitching moment variation with azimuth angle were in good overall agreementwith flight-test data, similar to other CFD results reported in the literature.b. The wake-grid resolution did not have a significant effect on the rotor-blade airloads. This surprisingresult indicates that a wake grid spacing of (Delta)S=10% ctip is sufficient for engineering airloads predictionfor hover and forward flight. This assumes high-resolution body grids, high-order spatial accuracy, anda hybrid RANS/DDES turbulence model.c. Three-dimensional dynamic stall was found to occur due the presence of blade-tip vortices passing overa rotor blade on the retreating side. This changed the local airfoil angle of attack, causing stall, unlikethe 2D perspective of pure pitch oscillation of the local airfoil section.

CFD Validation↗
NASA NTRS2017

Small Propeller and Rotor Testing Capabilities of the NASA Langley Low Speed Aeroacoustic Wind Tunnel

The Low Speed Aeroacoustic Wind Tunnel (LSAWT) at NASA Langley Research Center has recently undergone a configuration change. This change incorporates an inlet nozzle extension meant to serve the dual purposes of achieving lower free-stream velocities as well as a larger core flow region. The LSAWT, part of the NASA Langley Jet Noise Laboratory, had historically been utilized to simulate realistic forward flight conditions of commercial and military aircraft engines in an anechoic environment. The facility was modified starting in 2016 in order to expand its capabilities for the aerodynamic and acoustic testing of small propeller and unmanned aircraft system (UAS) rotor configurations. This paper describes the modifications made to the facility, its current aerodynamic and acoustic capabilities, the propeller and UAS rotor-vehicle configurations to be tested, and some preliminary predictions and experimental data for isolated propeller and UAS rotor con figurations, respectively. Isolated propeller simulations have been performed spanning a range of advance ratios to identify the theoretical propeller operational limits of the LSAWT. Performance and acoustic measurements of an isolated UAS rotor in hover conditions are found to compare favorably with previously measured data in an anechoic chamber and blade element-based acoustic predictions.

Zawodny, Nikolas S.↗
NASA NTRS2017

Evaluation of Methods for In-Situ Calibration of Field-Deployable Microphone Phased Arrays

Current field-deployable microphone phased arrays for aeroacoustic flight testing require the placement of hundreds of individual sensors over a large area. Depending on the duration of the test campaign, the microphones may be required to stay deployed at the testing site for weeks or even months. This presents a challenge in regards to tracking the response (i.e., sensitivity) of the individual sensors as a function of time in order to evaluate the health of the array. To address this challenge, two different methods for in-situ tracking of microphone responses are described. The first relies on the use of an aerial sound source attached as a payload on a hovering small Unmanned Aerial System (sUAS) vehicle. The second relies on the use of individually excited ground-based sound sources strategically placed throughout the array pattern. Testing of the two methods was performed in microphone array deployments conducted at Fort A.P. Hill in 2015 and at Edwards Air Force Base in 2016. The results indicate that the drift in individual sensor responses can be tracked reasonably well using both methods. Thus, in-situ response tracking methods are useful as a diagnostic tool for monitoring the health of a phased array during long duration deployments.

Humphreys, William M.↗
NASA NTRS2017

Microstructure Based Material-Sand Particulate Interactions and Assessment of Coatings for High Temperature Turbine Blades

Gas turbine engines for military/commercial fixed-wing and rotary wing aircraft use thermal barrier coatings in the high-temperature sections of the engine for improved efficiency and power. The desire to further make improvements in gas turbine engine efficiency and high power-density is driving the research and development of thermal barrier coatings and the effort of improving their tolerance to fine foreign particulates that may be contained in the intake air. Both commercial and military aircraft engines often are required to operate over sandy regions such as in the Middle-East nations, as well as over volcanic zones. For rotorcraft gas turbine engines, the sand ingestion is adverse during take-off, hovering near ground, and landing conditions. Although, most of the rotorcraft gas turbine engines are fitted with inlet particle separators, they are not 100 percent efficient in filtering fine sand particles of size 75 microns or below. The presence of these fine solid particles in the working fluid medium has an adverse effect on the durability of turbine blade thermal barrier coatings and overall performance of the engine. Typical turbine blade damages include blade coating wear, sand glazing, Calcia-Magnesia-Alumina-Silicate (CMAS) attack, oxidation, plugged cooling holes, all of which can cause rapid performance deterioration including loss of aircraft. The objective of this research is to understand the fine particle interactions with typical ceramic coatings of turbine blades at the microstructure level. A finite-element based microstructure modeling and analysis has been performed to investigate particle-surface interactions, and restitution characteristics. Experimentally, a set of tailored thermal barrier coatings and surface treatments were down-selected through hot burner rig tests and then applied to first stage nozzle vanes of the Gas Generator Turbine of a typical rotorcraft gas turbine engine. Laser Doppler velocity measurements were performed during hot burner rig testing to determine sand particle incoming velocities and their rebound characteristics upon impact on coated material targets. Further, engine sand ingestion tests were carried out to test the CMAS tolerance of the coated nozzle vanes. The findings from this on-going collaborative research to develop the next-gen sand tolerant coatings for turbine blades are presented in this paper.

Engine Tests↗
NASA NTRS2015

Quantifying Mapping Orbit Performance in the Vicinity of Primitive Bodies

Predicting and quantifying the capability of mapping orbits in the vicinity of primitive bodies is challenging given the complex orbit geometries that exist and the irregular shape of the bodies themselves. This paper employs various quantitative metrics to characterize the performance and relative effectiveness of various types of mapping orbits including terminator, quasi-terminator, hovering, ping pong, and conic-like trajectories. Metrics of interest include surface area coverage, lighting conditions, and the variety of viewing angles achieved. The metrics discussed in this investigation are intended to enable mission designers and project stakeholders to better characterize candidate mapping orbits during preliminary mission formulation activities. The goal of this investigation is to understand the trade space associated with carrying out remote sensing campaigns at small primitive bodies in the context of a robotic space mission. Specifically, this study seeks to understand the surface viewing geometries, ranges, etc. that are available from several commonly proposed mapping orbits architectures

Pavlak, Thomas A.↗
NASA NTRS2017

3D-Sonification for Obstacle Avoidance in Brownout Conditions

Helicopter brownout is a phenomenon that occurs when making landing approaches in dusty environments, whereby sand or dust particles become swept up in the rotor outwash. Brownout is characterized by partial or total obscuration of the terrain, which degrades visual cues necessary for hovering and safe landing. Furthermore, the motion of the dust cloud produced during brownout can lead to the pilot experiencing motion cue anomalies such as vection illusions. In this context, the stability and guidance control functions can be intermittently or continuously degraded, potentially leading to undetected surface hazards and obstacles as well as unnoticed drift. Safe and controlled landing in brownout can be achieved using an integrated presentation of LADAR and RADAR imagery and aircraft state symbology. However, though detected by the LADAR and displayed on the sensor image, small obstacles can be difficult to discern from the background so that changes in obstacle elevation may go unnoticed. Moreover, pilot workload associated with tracking the displayed symbology is often so high that the pilot cannot give sufficient attention to the LADAR/RADAR image. This paper documents a simulation evaluating the use of 3D auditory cueing for obstacle avoidance in brownout as a replacement for or compliment to LADAR/RADAR imagery.

3D audio↗
NASA NTRS2017

Joint Eglin Acoustics Week 2013 Data Report

Far-field acoustic measurements were obtained for the AH-64D, HH-60M and CV-22B at the Eglin AFB, Test Area C-72, in July/August 2013. The primary purpose for this flight test was to obtain a benchmark database of detailed acoustic source noise characteristics for the aircraft operating at typical mission gross weights over a range of typical mission operating conditions. Data were acquired for a range of steady-state level and descending flight conditions, hover, and a variety of unsteady maneuver conditions. Between 30 and 37 microphones were deployed during these tests. Vehicle position and state data, as well as weather data were acquired simultaneously with the acoustic data. This paper describes the test aircraft, onboard instrumentation, ground instrumentation, and the data acquired. Data from this test are available upon request and review.

Conner, David A.↗
NASA NTRS2017

Greased Lightning (GL-10) Performance Flight Research: Flight Data Report

Modern aircraft design methods have produced acceptable designs for large conventional aircraft performance. With revolutionary electronic propulsion technologies fueled by the growth in the small UAS (Unmanned Aerial Systems) industry, these same prediction models are being applied to new smaller, and experimental design concepts requiring a VTOL (Vertical Take Off and Landing) capability for ODM (On Demand Mobility). A 50% sub-scale GL-10 flight model was built and tested to demonstrate the transition from hover to forward flight utilizing DEP (Distributed Electric Propulsion)[1][2]. In 2016 plans were put in place to conduct performance flight testing on the 50% sub-scale GL-10 flight model to support a NASA project called DELIVER (Design Environment for Novel Vertical Lift Vehicles). DELIVER was investigating the feasibility of including smaller and more experimental aircraft configurations into a NASA design tool called NDARC (NASA Design and Analysis of Rotorcraft)[3]. This report covers the performance flight data collected during flight testing of the GL-10 50% sub-scale flight model conducted at Beaver Dam Airpark, VA. Overall the flight test data provides great insight into how well our existing conceptual design tools predict the performance of small scale experimental DEP concepts. Low fidelity conceptual design tools estimated the (L/D)( sub max)of the GL-10 50% sub-scale flight model to be 16. Experimentally measured (L/D)( sub max) for the GL-10 50% scale flight model was 7.2. The aerodynamic performance predicted versus measured highlights the complexity of wing and nacelle interactions which is not currently accounted for in existing low fidelity tools.

McSwain, Robert G.↗
NASA NTRS2018

High-Fidelity Computational Aerodynamics of Multi-Rotor Unmanned Aerial Vehicles

High-fidelity Computational Fluid Dynamics (CFD) simulations have been carried out for several multi-rotor Unmanned Aerial Vehicles (UAVs). Three vehicles have been studied: the classic quadcopter DJI Phantom 3, an unconventional quadcopter specialized for forward flight, the SUI Endurance, and an innovative concept for Urban Air Mobility (UAM), the Elytron 4S UAV. The three-dimensional unsteady Navier-Stokes equations are solved on overset grids using high-order accurate schemes, dual-time stepping, and a hybrid turbulence model. The DJI Phantom 3 is simulated with different rotors and with both a simplified airframe and the real airframe including landing gear and a camera. The effects of weather are studied for the DJI Phantom 3 quadcopter in hover. The SUI En- durance original design is compared in forward flight to a new configuration conceived by the authors, the hybrid configuration, which gives a large improvement in forward thrust. The Elytron 4S UAV is simulated in helicopter mode and in airplane mode. Understanding the complex flows in multi-rotor vehicles will help design quieter, safer, and more efficient future drones and UAM vehicles.

High-Fidelity↗
NASA NTRS2017

Investigation of Rotor-Airframe Interaction Noise Associated with Small-Scale Rotary-Wing Unmanned Aircraft Systems

In this study, hover acoustic measurements are taken on isolated rotor-airframe configurations representative of smallscale, rotary-wing unmanned aircraft systems (UAS). Each rotor-airframe configuration consists of two fixed-pitch blades powered by a brushless motor, with a simplified airframe geometry intended to represent a generic multicopter arm. In addition to acoustic measurements, CFD-based aeroacoustic predictions are implemented on a subset of the experimentally tested rotor-airframe configurations in an effort to better understand the noise content of the rotor-airframe systems. Favorable agreements are obtained between acoustic measurements and predictions, based on both time- and frequency-domain post-processing techniques. Results indicate that close proximity of airframe surfaces result in the generation of considerable tonal acoustic content in the form of harmonics of the rotor blade passage frequency (BPF). Analysis of the acoustic prediction data shows that the presence of the airframe surfaces can generate noise levels either comparable to or greater than the rotor blade surfaces under certain rotor tip clearance conditions. Analysis of the on-surface Ffowcs Williams and Hawkings (FW-H) source terms provide insight as to the predicted physical noise-generating mechanisms on the rotor and airframe surfaces.

Zawodny, Nikolas S.↗
NASA NTRS2016

Second-Generation Large Civil Tiltrotor 7- by 10-Foot Wind Tunnel Test Data Report

An approximately 6-percent scale model of the NASA Second-Generation Large Civil Tiltrotor (LCTR2) Aircraft was tested in the U.S. Army 7- by 10-Foot Wind Tunnel at NASA Ames Research Center January 4 to April 19, 2012, and September 18 to November 1, 2013. The full model was tested, along with modified versions in order to determine the effects of the wing tip extensions and nacelles; the wing was also tested separately in the various configurations. In both cases, the wing and nacelles used were adopted from the U.S. Army High Efficiency Tilt Rotor (HETR) aircraft, in order to limit the cost of the experiment. The full airframe was tested in high-speed cruise and low-speed hover flight conditions, while the wing was tested only in cruise conditions, with Reynolds numbers ranging from 0 to 1.4 million. In all cases, the external scale system of the wind tunnel was used to collect data. Both models were mounted to the scale using two support struts attached underneath the wing; the full airframe model also used a third strut attached at the tail. The collected data provides insight into the performance of the preliminary design of the LCTR2 and will be used for computational fluid dynamics (CFD) validation and the development of flight dynamics simulation models.

Theodore, Colin R.↗
NASA NTRS2018

Vertical Takeoff and Landing Vehicle with Increased Cruise Efficiency

Systems, methods, and devices are provided that combine an advance vehicle configuration, such as an advanced aircraft configuration, with the infusion of electric propulsion, thereby enabling a four times increase in range and endurance while maintaining a full vertical takeoff and landing ("VTOL") and hover capability for the vehicle. Embodiments may provide vehicles with both VTOL and cruise efficient capabilities without the use of ground infrastructure. An embodiment vehicle may comprise a wing configured to tilt through a range of motion, a first series of electric motors coupled to the wing and each configured to drive an associated wing propeller, a tail configured to tilt through the range of motion, a second series of electric motors coupled to the tail and each configured to drive an associated tail propeller, and an electric propulsion system connected to the first series of electric motors and the second series of electric motors.

Fredericks, William J.↗
NASA NTRS2018

Results of NASA Technical Challenge to Demonstrate Two-Speed Drive for Vertical Lift Vehicle

Currently, manned vertical lift vehicles are flown in a manner such that the rotors operate over a narrow range of rotating speed regardless if the vehicle's flight condition is one of vertical takeoff and landing, hover, or forward cruise. The propulsion systems are optimized for operation at the same, corresponding narrow range of rotor speed. However, certain missions and markets benefit greatly if the rotor speed can be adjusted over a wide range of speed to match demands of different missions and flight regimes. A vehicle that can operate with a wide range of rotor speeds would address key barriers to enable new markets and missions for vertical lift vehicles. Key barriers addressed by the wide-range of rotor speed include noise reduced via lower rpm rotor, increase of maximum forward flight speed, increased payload and range, reduced fuel burn, and lower operating costs. A new paradigm for the propulsion system is needed to enable these key benefits. One viable approach is to make use of a two-speed ratio drive system such that the engine can continue to operate over a narrow speed range, whereby engine performance is optimal, while adjusting the rotor speed as needed using the two-speed drive system. Motivated by such needs and by results of several system studies, a NASA Revolutionary Vertical Lift Technology Challenge was established to develop and demonstrate required technologies and designs for achieving a 50% reduction in rotor rpm via a two-speed drive system that incurs less than 2% power loss and maintains current power-to-weight ratios. The technical challenge work was completed and the technical objectives were achieved. This report describes the motivations, the research approach and the significant outcomes.

Transmissions↗
NASA NTRS2018

Aerodynamics and Aeroacoustic Sources of a Coaxial Rotor

Vehicles with coaxial, contra-rotating rotor systems (CACR) are being considered for a range of applications. Design parameters are identified that effect the fundamental aerodynamics and fluid dynamic features of a CACR in hover, vertical, and edgewise flight. Understanding the fluid dynamic features is a precursor to studying the aeroacoustics of a coaxial rotor. Rotor performance was computed initially using Navier-Stokes solver with prescribed blade section aerodynamic properties, the results validated against generic experimental test cases. Using a A 2D potential flow code and 2D OVERFLOW compressible-flow Navier-Stokes solver, the fluid dynamics of blade interactions was simplified and broken into a 2D blade crossing problem, with crossing locations and velocity fields from the rotor results to understand circulation, thickness, compressibility, shed vorticity, downwash, and viscosity effects. A calculation tool has been developed to identify time and location of blade overlap and BVI time location for CACR. Specific aerodynamic phenomena that occur for each noise source relevant to CACR are presented, along with computational tools to predict these occurrences.

Aeroacoustic↗
NASA NTRS2018

Using Liquid Natural Gas Fuel to Cryogenically Cool and Enhance a Hybrid Electric Aircraft Power System

A previous system study identified significant increases in range and number of urban air mobility (UAM) missions by replacing the all battery power system of a notional UAM vehicle with an advanced diesel hybrid using conventional diesel or liquid natural gas (LNG) fuels (at constant vehicle design gross weight). Some benefits were realized using the LNG's cryogenic properties to reduce some electrical component losses and cooling requirements. Significant questions were raised concerning volume and thermal management considerations for all studied systems. The notional, baseline vehicle was a hybrid helicopter / airplane design capable of vertical take-off and landing (VTOL), balancing high cruise efficiency with reasonable hover capability. A subsequent power system assessment using the same notional vehicle and mission was performed that identified increased volume and power requirements for the active cooling required. The cooling airflow could also generate additional drag on the vehicle during operation. For the notional vehicle studied, the additional volume identified by the subsequent study would not affect vehicle mold line and therefore drag. However, the additional drag from cooling airflow and the power to circulate it as needed would impact power system and vehicle mission performance. Vehicle and mission models were updated and rerun. Updated results still indicated significant benefits in range and number of UAM missions, but reduced the benefit by 12-15%. Hold time for the hybrid systems also generally increased a few minutes because of reduced power available for charging from the power for required cooling flows. Vehicle weights, thermal loads, and cooling airflows from the updated analyses were similar to previous results.

systems analysis↗
NASA NTRS2018

Development and Validation of Physics Based Models for Ice Shedding

Calculations for ice accretion and shedding are presented for a model scale rotor in hover. The aerodynamic characteristics of the rotor are first computed using a combined blade element-momentum theory. The effective angles of attack, and the local flow velocity are used within the NASA Glenn solver LEWICE to estimate the collection efficiency. The computed convection efficiency and the surface pressure distribution from a panel method within LEWICE are used to estimate the ice accretion over the rotor blades over an elapsed time interval. Finally, a force balance approach is used to establish shedding events where the centrifugal force over the ice mass exceeds the adhesive forces at the rotor surface and the cohesive forces between adjacent masses of ice. Preliminary comparisons with test data acquired at the Pennsylvania State Icing Research Tunnel are presented. Sensitivity of the ice shedding events to surface roughness, adhesive strength, cohesive strength, and ambient conditions is discussed.

Gupta, Avani↗
NASA NTRS2018

A Physics-Based Approach to Urban Air Mobility

High-fidelity Computational Fluid Dynamics (CFD) simulations for multi-rotor vehicles have been carried out. The three-dimensional unsteady Navier-Stokes equations are solved on overset grids employing high order accurate schemes, dual-time stepping, and a hybrid turbulence model using NASA's CFD code Over- flow. The vehicles studied consist of small to medium sized drones, and bigger vehicles for future Urban Air Mobility (UAM) applications. The performances for different configurations and rotor mounting are calculated in hover and in forward flight. Understanding the complex flows and the interactions between rotors and with other elements will help design the future multi-rotor vehicles to be quieter, safer, and more efficient.

Urban↗