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At least 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS2021

Wake Instability Behind Isolated Trip Near the Leading Edge of the BOLT-II Configuration

The BOLT-II (Holden Mission) configuration is an extended version of the BOLT flight article and depicts hypersonic boundary-layer transition in the presence of multiple and potentially interacting instability mechanisms. Several numerical studies of the boundary-layer instabilities over these configurations have been reported in the recent literature, including our previous studies of the modal instability characteristics of boundary-layer streaks adjacent to the minor-axis symmetry plane of the BOLT configuration and the wake instabilities behind a diamond planform (“pizza-box”) trip along the symmetry plane on the secondary side of the BOLT-II configuration. The present work extends the latter study to a scaled version of the same trip that is located in the region of nonzero crossflow in the vicinity of the leading edge at X/L = 0.5. Collectively, the trips along the symmetry plane and near the leading edge are the focus of the NASA roughness experiment on the secondary side of the BOLT-II configuration. The laminar basic state computation at the nominal flight design condition of Re ∞ = 5.44 x 10 6 /m and Re ∞ = 2.5 x 10 6 /m shows that the leading-edge trip with k/δ ≈ 0.70 and planform-side-length-to-height ratio of b/k = 3.0 induces multiple asymmetric, longitudinal streaks within the trip wake. The most prominent streak among these resembles a finite amplitude crossflow vortex, and it supports the amplification of multiple families of unstable modes. The application of multi-dimensional instability analysis to the wake flow reveals that the most amplified unstable mode can achieve a peak N-factor of up to 20 by X/L = 0.80, indicating that the onset of transition is more than likely to occur within eighty percent of the model length. To the best of our knowledge, the present study represents the first analysis including nonparallel and curvature effects on hypersonic tripwake instabilities in the presence of boundary-layer crossflow over a three-dimensional configuration.

Boundary layer transition↗
NASA NTRSDate not supplied

Development of the BOLT II Roughness Experiment for Flight

BOLT II is a sounding rocket research project with the goal of studying hypersonic boundary layer transition and turbulence. The BOLT II research vehicle is based on a three-dimensional geometry (a slightly longer version of BOLT) with concave surfaces and swept leading edges that provides two separate and distinct, also redundant, flow paths for conducting measurements. One side of BOLT II is dedicated to smooth surface transition and turbulence, to better study the natural instability processes, while the other has been assigned to study forced transition and turbulence using discrete roughness trips. The present paper is intended to document the primary drivers and decisions made leading up to finalizing the roughness side experiment for the BOLT II flight.

Hypersonic↗
NASA NTRSDate not supplied

Development of the BOLT II Roughness Experiment for Flight

BOLT II is a sounding rocket research project with the goal of studying hypersonic boundary layer transition and turbulence. The BOLT II research vehicle is based on a three-dimensional geometry (a slightly longer version of BOLT) with concave surfaces and swept leading edges that provides two separate and distinct, also redundant, flow paths for conducting measurements. One side of BOLT II is dedicated to smooth surface transition and turbulence, to better study the natural instability processes, while the other has been assigned to study forced transition and turbulence using discrete roughness trips. The present paper is intended to document the primary drivers and decisions made leading up to finalizing the roughness side experiment for the BOLT II flight.

hypersonic↗
NASA NTRS2021

Transition Analysis for Isolated Trips on BOLT-II Wind-Tunnel and Flight Configuration

The BOLT-II configuration designed for an upcoming flight experiment exemplifies the complexities of hypersonic boundary layer transition in the presence of multiple and potentially interacting instability mechanisms. The present paper is related to the NASA-led roughness experiment on the secondary side of the BOLT-II configuration. First, computations are performed to aid mean-flow based correlations for the transition measurements acquired during an experimental campaign in the Ludwieg Tube facility at the United States Air Force Academy. To that end, both laminar and turbulent flow computations are performed for selected conditions of the experiment with a 1:3 scale model of the slightly shorter BOLT configuration. The variation in well-known correlation parameters for transition due to isolated roughness elements with respect to element position, height, and flow Reynolds number is delineated. Furthermore, the wake instability theory is used to examine the amplification of unstable disturbances behind the centerline trip at the design conditions of the BOLT-II flight experiment and for its dynamically scaled version on the 1:3 scale model of the wind tunnel experiment. To our knowledge, this study represents the first analysis of the wake instabilities in the presence of a prominent entropy layer outside the boundary layer. At the nominal flight design condition of Re ∞ ) = 5.44 and Re ∞ = 2.5 x 10 6 /m, a diamond planform (“pizza-box”) trip with k/δ = 0.70 and planform-halfwidth-to-height ratio of b/k = 3.0 at X/L = 0.254 induces a strong distortion of the boundary-layer flow in the vicinity of the symmetry plane, such that the wake structure includes a centerline streak produced by the flow retardation behind the trip along with multiple additional, prominent vorticity structures representing the necklace vortex system. Stability results reveal that each of these streaks can support a strong amplification of wake instabilities within a frequency band of 95 kHz–255 kHz, with a peak N-factor of greater than 15 beyond X/L ≈ 0.42. The dynamically scaled wind tunnel configuration with Re ∞ = 20.25 x 10 6 /m is also found to support N > 15 at similar axial stations.

BOLT↗
NASA NTRS2021

Transition Analysis for Isolated Trips on BOLT-II Wind-Tunnel and Flight Configuration

The BOLT-II configuration designed for an upcoming flight experiment exemplifies the complexities of hypersonic boundary layer transition in the presence of multiple and potentially interacting instability mechanisms. The present paper is related to the NASA-led roughness experiment on the secondary side of the BOLT-II configuration. First, computations are performed to aid mean-flow based correlations for the transition measurements acquired during an experimental campaign in the Ludwieg Tube facility at the United States Air Force Academy. To that end, both laminar and turbulent flow computations are performed for selected conditions of the experiment with a 1:3 scale model of the slightly shorter BOLT configuration. The variation in well-known correlation parameters for transition due to isolated roughness elements with respect to element position, height, and flow Reynolds number is delineated. Furthermore, the wake instability theory is used to examine the amplification of unstable disturbances behind the centerline trip at the design conditions of the BOLT-II flight experiment and for its dynamically scaled version on the 1:3 scale model of the wind tunnel experiment. To our knowledge, this study represents the first analysis of the wake instabilities in the presence of a prominent entropy layer outside the boundary layer. At the nominal flight design condition of Re ∞ ) = 5.44 and Re ∞ = 2.5 x 10 6 /m, a diamond planform (“pizza-box”) trip with k/δ = 0.70 and planform-halfwidth-to-height ratio of b/k = 3.0 at X/L = 0.254 induces a strong distortion of the boundary-layer flow in the vicinity of the symmetry plane, such that the wake structure includes a centerline streak produced by the flow retardation behind the trip along with multiple additional, prominent vorticity structures representing the necklace vortex system. Stability results reveal that each of these streaks can support a strong amplification of wake instabilities within a frequency band of 95 kHz–255 kHz, with a peak N-factor of greater than 15 beyond X/L ≈ 0.42. The dynamically scaled wind tunnel configuration with Re ∞ = 20.25 x 10 6 /m is also found to support N > 15 at similar axial stations.

BOLT↗
NASA NTRSDate not supplied

BOLT II Roughness-Side Flight Results

An initial review of the roughness data from the BOLT II flight is provided. The BOLT II roughness experiment was designed to investigate discrete trips in flight based on the diamond configuration, which has been shown to be an efficient vortex generator and boundary layer trip from extensive ground-based testing. There were three trip locations chosen for the flight test and their size (height and width) were tailored to the local boundary layer thickness, but all three were expected to trip at the same time or flight condition. Details about the flight vehicle design, instrumentation, and best estimated trajectory are discussed. The present paper is limited to only a review and analysis of the thermocouple data. Boundary layer transition onset times are derived from the thermocouple analysis, thus allowing an initial assessment of the performance of these discrete trips. Since the three trips were sized to trip the boundary layer at the same time, based on a previous wind tunnel study, the present analysis indicates that they performed as expected.

Hypersonic↗
NASA NTRS2023

BOLT II Forebody Surface Measurement Analysis

Surface impression molds of the nosetip/forebody interface, discrete tripping elements, and other surface imperfections were formed on the BOLT II flight vehicle prior to its launch in March 2022. The silicon-rubber molds cast on the interface between the nickel nosetip and the stainless steel forebody were measured using a 3D optical measurement system and a stylus profilometer and were evaluated for step direction and height. The step around the nosetip/forebody interface was found to vary in both magnitude and direction, but values were generally modest with most samples below 60 μm across the span and only two samples, both cast in the gutter, with step values larger than 100 μm. Impressions of the secondary-side tripping elements were strictly scanned with the optical device and similar methods were used to calculate trip height as step height. The measured centerline trip height was 2623 ±12 μm, while the leading-edge, quadrant 2 and 3, trip heights were 897 ±5 μm and 891 ±18 μm, respectively. Surface imperfections on the nose and forebody were also evaluated. Surface roughness values and spectra were estimated, and profiles were extracted across the imperfections to quantify the magnitude of those features.

Trip height↗
NASA NTRSDate not supplied

Recent BOLT Discrete-Roughness Trip Results from the 20-Inch Mach 6 Tunnel

- Air Force Office of Scientific Research (AFOSR) primary sponsor of BOLT (for Boundary Layer Transition) sounding rocket flight project as continuation of previous HIFiRE flights (1 & 5) - Sounding rockets provide cost-effective flight research tool - Study hypersonic BoLT on increasingly complex geometries - BOLT shape includes concave surfaces and swept leading edges - Two missions, two flights: - BOLT mission at Esrange, Sweden - Johns Hopkins University Applied Physics Laboratory as lead - Focus on transition onset measurements - Flew June 2021 (staging anomaly) - BOLT II mission at Wallops Flight Facility, Virginia - Texas A&M and CUBRC provide primary leadership - Focus on turbulence measurements - Flew March 2022 - Flight named in memory of Mike Holden - NASA’s support to both BOLT missions provided through the Hypersonic Technologies Project (HTP)

Hypersonic↗
NASA NTRSDate not supplied

Development of Optical Step Height Measurement Capability for the BOLT Flight Vehicle

This paper presents details on the development of testing procedures to evaluate two different optical step height sensors that were intended for use on the first and second Boundary Layer Transition (BOLT and BOLT II) flight vehicle as well as other flight vehicles. The accurate and precise measurement of step height at the interface of different sections of a flight vehicle is important, as small changes in the step height (in some instances < 10 microns) at such locations can have a significant influence on the development of a boundary layer over the outer surface of the vehicle, which in turn can significantly impact aeroheating (among other things). In this paper, testing procedures have been developed, and test hardware assembled, to determine the capabilities of two optical step height sensor candidates. The first candidate is a miniaturized camera sensor that would be embedded into the body of a flight vehicle and would image the interface between two sections of that vehicle. The second candidate is a small fiber-based optical sensor that would also be embedded into the body of the flight vehicle, but projects light onto the interface between two sections of the flight vehicle, and then monitors any reflected/scattered light from that interface. Preliminary data from these two sensor candidates are presented, and a discussion of improvements that will be made in the testing procedures and to the test hardware is provided.

Brett F Bathel↗
NASA NTRS2016

Free-Piston Stirling Power Conversion Unit for Fission Power System, Phase II Final Report

In Phase II, the manufacture and testing of two 6-kW(sub e)Stirling engines was completed. The engines were delivered in an opposed 12-kW(sub e) arrangement with a common expansion space heater head. As described in the Phase I report, the engines were designed to be sealed both hermetically and with a bolted O-ring seal. The completed Phase II convertor is in the bolted configuration to allow future disassembly. By the end of Phase II, the convertor had passed all of the final testing requirements in preparation for delivery to the NASA Glenn Research Center. The electronic controller also was fabricated and tested during Phase II. The controller sets both piston amplitudes and maintains the phasing between them. It also sets the operating frequency of the machine. Details of the controller are described in the Phase I final report. Fabrication of the direct-current to direct-current (DC-DC) output stage, which would have stepped down the main controller output voltage from ~700 to 120 V(sub DC), was omitted from this phase of the project for budgetary reasons. However, the main controller was successfully built, tested with the engines, and delivered. We experienced very few development issues with this high-power controller. The project extended significantly longer than originally planned because of yearly funding delays. The team also experienced several hardware difficulties along the development path. Most of these were related to the different thermal expansions of adjacent parts constructed of different materials. This issue was made worse by the large size of the machine. Thermal expansion problems also caused difficulties in the brazing of the opposed stainless steel sodium-potassium (NaK) heater head. Despite repeated attempts Sunpower was not able to successfully braze the opposed head under this project. Near the end of the project, Glenn fabricated an opposed Inconel NaK head, which was installed prior to delivery for testing at Glenn. Engine development prior to this was performed using both single- and dual-opposed (common expansion space) Inconel heads with clamp-on electric heaters.

Free-piston Stirling Power Conversion Unit↗
NASA NTRSDate not supplied

Transition prediction in hypersonic regime on complex geometries with RANS-based models

In the near future, RANS computations will continue to play a significant role in the design of hypersonic vehicles with complex geometries. Therefore, it is imperative to continue testing, benchmarking, and refining the RANS models. In the present study, we evaluate RANS-like, transport equations-based models for predicting laminar-turbulent transition over a full-scale scale model of the BOLT flight configuration that was tested in the CUBRC LENS-II wind tunnel test facility. Based on the availability of the experimental results, comparisons are made between computations from several pre-existing transition models and Computational Fluid Dynamics (CFD) codes, with an emphasis on using the same computational meshes and flow conditions for all computations. The analysis covers the sensitivity of the transition predictions to the input parameters for five different transition models (four mainstream models designed for low-speed flows and a uniquely high-speed model), grid resolution, and the details of model implementation across three different flow solvers. The results show that the phenomenological models can describe significant aspects of the measured transition front. However, a number of additional improvements are required before these models can offer more reliable estimates of transition in high-speed flows.

CFD↗
NASA NTRSDate not supplied

Transition Prediction in Hypersonic Regime on Complex Geometries With Rans-Based Models

In the near future, RANS computations will continue to play a significant role in the design of hypersonic vehicles with complex geometries. Therefore, it is imperative to continue testing, benchmarking, and refining the RANS models. In the present study, we evaluate RANS-like, transport equations-based models for predicting laminar-turbulent transition over a full-scale scale model of the BOLT flight configuration that was tested in the CUBRC LENS-II wind tunnel test facility. Based on the availability of the experimental results, comparisons are made between computations from several pre-existing transition models and Computational Fluid Dynamics (CFD) codes, with an emphasis on using the same computational meshes and flow conditions for all computations. The analysis covers the sensitivity of the transition predictions to the input parameters for five different transition models (four mainstream models designed for low-speed flows and a uniquely high-speed model), grid resolution, and the details of model implementation across three different flow solvers. The results show that the phenomenological models can describe significant aspects of the measured transition front. However, a number of additional improvements are required before these models can offer more reliable estimates of transition in high-speed flows.

CFD↗
NASA NTRS2012

Process Sensitivity, Performance, and Direct Verification Testing of Adhesive Locking Features

Phase I: The use of adhesive locking features or liquid locking compounds (LLCs) (e.g., Loctite) as a means of providing a secondary locking feature has been used on NASA programs since the Apollo program. In many cases Loctite was used as a last resort when (a) self-locking fasteners were no longer functioning per their respective drawing specification, (b) access was limited for removal & replacement, or (c) replacement could not be accomplished without severe impact to schedule. Long-term use of Loctite became inevitable in cases where removal and replacement of worn hardware was not cost effective and Loctite was assumed to be fully cured and working. The NASA Engineering & Safety Center (NESC) and United Space Alliance (USA) recognized the need for more extensive testing of Loctite grades to better understand their capabilities and limitations as a secondary locking feature. These tests, identified as Phase I, were designed to identify processing sensitivities, to determine proper cure time, the correct primer to use on aerospace nutplate, insert and bolt materials such as A286 and MP35N, and the minimum amount of Loctite that is required to achieve optimum breakaway torque values. The .1900-32 was the fastener size tested, due to wide usage in the aerospace industry. Three different grades of Loctite were tested. Results indicate that, with proper controls, adhesive locking features can be successfully used in the repair of locking features and should be considered for design. Phase II: Threaded fastening systems used in aerospace programs typically have a requirement for a redundant locking feature. The primary locking method is the fastener preload and the traditional redundant locking feature is a self-locking mechanical device that may include deformed threads, non-metallic inserts, split beam features, or other methods that impede movement between threaded members. The self-locking resistance of traditional locking features can be directly verified during assembly by measuring the dynamic prevailing torque. Adhesive locking features or LLCs are another method of providing redundant locking, but a direct verification method has not been used in aerospace applications to verify proper installation when using LLCs because of concern for damage to the adhesive bond. The reliability of LLCs has also been questioned due to failures observed during testing with coupons for process verification, although the coupon failures have often been attributed to a lack of proper procedures. It is highly desirable to have a direct method of verifying the LLC cure or bond integrity. The purpose of the Phase II test program was to determine if the torque applied during direct verification of an adhesive locking feature degrades that locking feature. This report documents the test program used to investigate the viability of such a direct verification method. Results of the Phase II testing were positive, and additional investigation of direct verification of adhesive locking features is merited.

Golden, Johnny L.↗
NASA NTRS2003

Columbia Accident Investigation Board Report. Volume Two

Volume II of the Report contains appendices that were cited in Volume I. The Columbia Accident Investigation Board produced many of these appendices as working papers during the investigation into the February 1, 2003 destruction of the Space Shuttle Columbia. Other appendices were produced by other organizations (mainly NASA) in support of the Board investigation. In the case of documents that have been published by others, they are included here in the interest of establishing a complete record, but often at less than full page size. Contents include: CAIB Technical Documents Cited in the Report: Reader's Guide to Volume II; Appendix D. a Supplement to the Report; Appendix D.b Corrections to Volume I of the Report; Appendix D.1 STS-107 Training Investigation; Appendix D.2 Payload Operations Checklist 3; Appendix D.3 Fault Tree Closure Summary; Appendix D.4 Fault Tree Elements - Not Closed; Appendix D.5 Space Weather Conditions; Appendix D.6 Payload and Payload Integration; Appendix D.7 Working Scenario; Appendix D.8 Debris Transport Analysis; Appendix D.9 Data Review and Timeline Reconstruction Report; Appendix D.10 Debris Recovery; Appendix D.11 STS-107 Columbia Reconstruction Report; Appendix D.12 Impact Modeling; Appendix D.13 STS-107 In-Flight Options Assessment; Appendix D.14 Orbiter Major Modification (OMM) Review; Appendix D.15 Maintenance, Material, and Management Inputs; Appendix D.16 Public Safety Analysis; Appendix D.17 MER Manager's Tiger Team Checklist; Appendix D.18 Past Reports Review; Appendix D.19 Qualification and Interpretation of Sensor Data from STS-107; Appendix D.20 Bolt Catcher Debris Analysis.

CAIB (COLUMBIA ACCIDENT INVESTIGATION BOARD)↗
NASA NTRS1993

Double Cantilever Beam and End Notched Flexure Fracture Toughness Testing of Two Composite Materials

Two different unidirectional composite materials were provided by NASA Langley Research Center and tested by the Composite Materials Research Group within the Department of Mechanical Engineering at the University of Wyoming. Double cantilever beam and end notched flexure tests were performed to measure the mode I (crack opening) and mode II (sliding or shear) interlaminar fracture toughness of the two materials. The two composites consisted of IM7 carbon fiber combined with either RP46 resin toughened with special formulation of LaRC IA resin, known as JJS1356; or PES chain extended thermoplastic resin known as JJS1361. Double Cantilever Beam Specimen Configuration and Test Methods As received from NASA, the test specimens were nominally 0.5 inch wide, 6 inches long, and 0.2 inch thick. A 1 inch long Kapton insert at the midplane of one end of the specimen (placed during laminate fabrication) facilitated crack initiation and extension. It was noted that the specimens provided were smaller than the nominal 1.5 inch wide, 9.0 inch long configuration specified. Similarly, the Kapton inserts were of greater length than those in the present specimens. Hence, the data below should not be compared directly to those generated with the referenced methods. No preconditioning was performed on the specimens prior to testing. In general, the methodology was used for the present work. Crack opening loads were introduced to the specimens via piano hinges attached to the main specimen faces at a single end of each specimen. Hinges were bolted to the specimens using the technique presented. The cracks were extended a small distance from the end of the Kapton insert prior to testing. Just before precracking, the sides of the specimens were coated with water-soluble typewriter correction fluid to aid in crack visualization. Scribe marks were then made in the coating at half-inch intervals.

Kessler, Jeff A.↗