Full Life Cycle Mach 6 Nozzle Testing at Long Duration
AETC 2022 Full Life Cycle Mach 6 Nozzle Testing at Long Duration Capability Challenge: Langley 8-Foot High Temperature Tunnel (HTT)
Mach 6 Nozzle↗
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Effect of the Reynolds Number on the Freestream Disturbance Environment in a Mach 6 Nozzle
To understand the impact of unit Reynolds number on the acoustic disturbance field inside a high-speed wind tunnel, we use Direct Numerical Simulations (DNS) to model the turbulent boundary layers along the walls of a quasi-two-dimensional nozzle configuration. Intended as a stepping stone to fully three-dimensional simulations of freestream noise inside the NASA 20-Inch Mach 6 Wind Tunnel, the present simulations are based on periodic boundary conditions across the spanwise width of the computational domain that corresponds to about one third of the actual tunnel width. These simulations are performed at four different unit Reynolds numbers, ranging from 3.56e6 to 14.0e6 per meter. The predominantly hydrodynamic fluctuations inside the boundary layer are shown to be nearly unaffected by the presence of freestream forcing associated with the impinging acoustic radiation from the opposite wall. Thus, the Reynolds number trends associated with boundary-layer quantities are consistent with previously published DNS of flat-plate boundary layers at similar Mach numbers and wall temperature ratios. The unsteady disturbance environment within the nozzle core region is found to be approximately spatially homogeneous and purely acoustic in nature. The numerical results are used to make comparisons with tunnel noise measurements by Chou et al. [1,2]. Unlike previous comparisons involving static-pressure fluctuations based on the DNS and pitot-pressure fluctuations measured in the wind tunnel, direct comparisons involving the fluctuations in the same physical quantity, namely, the streamwise mass flux, have been reported for the first time. The predicted decrease in the root-mean-square fluctuations in pressure and mass flux with an increasing unit Reynolds number is in agreement with the measurements in the NASA 20-Inch Mach 6 Wind Tunnel. Additional details of the acoustic radiation field are quantified and should be useful toward a digital synthesis of the tunnel disturbance environment that would enable realistic simulations of the natural transition process.
Acoustics↗
Effect of the Reynolds Number on the Freestream Disturbance Environment in a Mach 6 Nozzle
To understand the impact of unit Reynolds number on the acoustic disturbance field inside a high-speed wind tunnel, we use Direct Numerical Simulations (DNS) to model the turbulent boundary layers along the walls of a quasi-two-dimensional nozzle configuration. Intended as a stepping stone to fully three-dimensional simulations of freestream noise inside the NASA 20-Inch Mach 6 Wind Tunnel, the present simulations are based on periodic boundary conditions across the spanwise width of the computational domain that corresponds to about one third of the actual tunnel width. These simulations are performed at four different unit Reynolds numbers, ranging from 3.56e6 to 14.0e6 per meter. The predominantly hydrodynamic fluctuations inside the boundary layer are shown to be nearly unaffected by the presence of freestream forcing associated with the impinging acoustic radiation from the opposite wall. Thus, the Reynolds number trends associated with boundary-layer quantities are consistent with previously published DNS of flat-plate boundary layers at similar Mach numbers and wall temperature ratios. The unsteady disturbance environment within the nozzle core region is found to be approximately spatially homogeneous and purely acoustic in nature. The numerical results are used to make comparisons with tunnel noise measurements by Chou et al. [1,2]. Unlike previous comparisons involving static-pressure fluctuations based on the DNS and pitot-pressure fluctuations measured in the wind tunnel, direct comparisons involving the fluctuations in the same physical quantity, namely, the streamwise mass flux, have been reported for the first time. The predicted decrease in the root-mean-square fluctuations in pressure and mass flux with an increasing unit Reynolds number is in agreement with the measurements in the NASA 20-Inch Mach 6 Wind Tunnel. Additional details of the acoustic radiation field are quantified and should be useful toward a digital synthesis of the tunnel disturbance environment that would enable realistic simulations of the natural transition process.
Turbulence↗
A Mach 6 external nozzle experiment with Argon-Freon exhaust simulation
A scramjet exhaust simulation technique for hypersonic wind tunnel testing has been developed. Mixtures of Argon and Freon correctly match the inviscid simulation parameters of Mach number, static-pressure ratio, and the ratio of specific heats at the combustor exit location; this simulation is accomplished at significantly reduced temperatures and without combustion. An investigation of nozzle parametrics in a Mach 6 freestream showed that the external nozzle ramp angle, the cowl trailing-edge angle, an external nozzle flow fence and the nozzle static-pressure ratio significantly affected the external nozzle thrust and pitching moment as measured by the integration of surface-pressure data. A comparison of Argon-Freon and air exhaust simulation showed that the external nozzle thrust and pitching moment were in error by roughly a factor of 2 using air due to the incorrect match of the ratio of specific heats. An assessment of two-dimensional Euler and Navier-Stokes codes for predicting external nozzle aerodynamic characteristics was made by comparing computed and experimental results.
Pittman, James L.↗
Computational and Experimental Characterization of the Mach 6 Facility Nozzle Flow for the Enhanced Injection and Mixing Project at NASA Langley Research Center
Computational fluid dynamics analyses and experimental data are presented for the Mach 6 facility nozzle used in the Arc-Heated Scramjet Test Facility for the Enhanced Injection and Mixing Project (EIMP). This project, conducted at the NASA Langley Research Center, aims to investigate supersonic combustion ramjet (scramjet) fuel injection and mixing physics relevant to flight Mach numbers greater than 8. The EIMP experiments use a two-dimensional Mach 6 facility nozzle to provide the high-speed air simulating the combustor entrance flow of a scramjet engine. Of interest are the physical extent and the thermodynamic properties of the core flow at the nozzle exit plane. The detailed characterization of this flow is obtained from three-dimensional, viscous, Reynolds-averaged simulations. Thermodynamic nonequilibrium effects are also investigated. The simulations are compared with the available experimental data, which includes wall static pressures as well as in-stream static pressure, pitot pressure and total temperature obtained via in-stream probes positioned just downstream of the nozzle exit plane.
Drozda, Tomasz G.↗
Pitot survey of exhaust flow field of a 2-D scramjet nozzle at Mach 6 with air or freon and argon used for exhaust simulation
A pitot-rake survey of the simulated exhaust of a half-span scramjet nozzle model was conducted in the Langley 20-Inch Mach 6 Tunnel to provide an additional data set for computational fluid dynamics (CFD) code comparisons. A wind-tunnel model was tested with a 26-tube pitot rake that could be manually positioned along the mid-semispan plane of the model. The model configuration had an external expansion surface of 20 degrees and an internal cowl expansion of 12 degrees; tests were also performed with a flow fence. Tests were conducted at a free-stream Reynolds number of approximately 6.5 x 10(exp 6) per foot and a model angle of attack of -0.75 degrees. The two exhaust gas mediums that were tested were air and a Freon 12-argon mixture. Each medium was tested at two jet total pressures at approximately 28 and 14 psia. This document presents the flow-field survey results in graphical as well as tabular form, and several observations concerning the results are discussed. The surveys reveal the major expected flow-field characteristics for each test configuration. For a 50-percent freon 12 and 50-percent argon mixture by volume (Fr-Ar), the exhaust jet pressures were slightly higher than those for air. The addition of a flow fence slightly raised the pitot pressure for the Fr-Ar mixture, but it produced little change for air. For the Fr-Ar exhaust, the plume was larger and the region between the shock wave and plume was smaller.
Monta, William J.↗
A parametric experimental investigation of a scramjet nozzle at Mach 6 with Freon and argon or air used for exhaust simulation
A parametric experimental investigation of a scramjet nozzle was conducted with a gas mixture used to simulate the scramjet engine exhaust flow at a free-stream Reynolds number of approximately 6.5 x 10(exp 6) per foot. External nozzle surface angles of 16, 20, and 24 deg were tested with a fixed-length ramp and for cowl internal surface angles of 6 and 12 deg. Pressure data on the external nozzle surface were obtained for mixtures of Freon and argon gases with a ratio of specific heats of about 1.23, which matches that of a scramjet exhaust. Forces and moments were determined by integration of the pressure data. Two nozzle configurations were also tested with air used to simulate the exhaust flow. On the external nozzle surface, lift and thrust forces for air exhaust simulation were approximately half of those for Freon-argon exhaust simulation and the pitching moment was approximately a third. These differences were primarily due to the difference in the ratios of specific heats between the two exhaust simulation gases. A 20 deg external surface angle produced the greatest thrust for a 6 deg cowl internal surface angle. A flow fence significantly increased lift and thrust forces over those for the nozzle without a flow fence.
Cubbage, James M.↗
Impact of Flight Enthalpy, Fuel Simulant, and Chemical Reactions on the Mixing Characteristics of Several Injectors at Hypervelocity Flow Conditions
The high total temperatures or total enthalpies required to duplicate the high-speed flight conditions in ground experiments often place stringent requirements on the material selection and cooling needs for the test articles and intrusive flow diagnostic equipment. Furthermore, for internal flows, these conditions often complicate the use of nonintrusive diagnostics that need optical access to the test section and interior portions of the flowpath. Because of the technical challenges and increased costs associated with experimentation at high values of total enthalpy, an attempt is often made to reduce it. This is the case for the Enhanced Injection and Mixing Project (EIMP) currently underway in the Arc-Heated Scramjet Test Facility at the NASA Langley Research Center. The EIMP aims to investigate supersonic combustion ramjet (scramjet) fuel injection and mixing physics, improve the understanding of underlying physical processes, and develop enhancement strategies and functional relationships between mixing performance and losses relevant to flight Mach numbers greater than 8. The experiments will consider a "direct-connect" approach and utilize a Mach 6 nozzle to simulate the combustor entrance flow of a scramjet engine. However, while the value of the Mach number is matched to that expected at the combustor entrance in flight, the maximum value of the total enthalpy for these experiments is limited by the thermal-structural limits of the uncooled experimental hardware. Furthermore, the fuel simulant is helium, not hydrogen. The use of "cold" flows and non-reacting mixtures of fuel simulants for mixing experiments is not new and has been extensively utilized as a screening technique for scramjet fuel injectors. In this study, Reynolds-averaged simulations are utilized (RAS) to systematically verify the implicit assumptions used by the EIMP. This is accomplished by first performing RAS of mixing for two injector configurations at planned nominal experimental conditions. The mixing parameters of interest, such as mixing efficiency and total pressure recovery, are then computed and compared to the values obtained from RAS under the true enthalpy conditions and using helium and hydrogen. Finally, the impact of combustion on mixing, often deemed small enough to neglect at hypervelocity conditions, is assessed by comparing the results obtained from the hydrogen-fueled reacting and non-reacting RAS. For reacting flows, in addition to mixing efficiency and total pressure recovery, the combustion efficiency and thrust potential are also considered. In all of the simulations, the incoming air Mach number and the fuel-to-air ratio are the same, while the total pressure, total enthalpy, and the fuel simulant vary depending on the case considered. It is found that under some conditions the "cold" flow experiments are a good approximation of the flight.
Drozda, Tomasz G.↗
Goertler instability and hypersonic quiet nozzle design
A concept for nozzle design which incorporates slow expansion rates and a radial flow region is developed for use on a hypersonic (Mach 6) nozzle. It is shown that the boundary-layer suction slot upstream of the nozzle throat is necessary to remove upstream turbulent boundary layers and to initialize a new laminar boundary layer on the downstream nozzle wall. In effect, the laminar boundary-layer flow can be extended more effectively farther downstream by a slow expansion contour based on the present design concept than by a rapid expansion contour used in previous pilot quiet nozzles.
Chen, Fang-Jenq↗
Langley 20-inch hypersonic CF4 tunnel - A facility for simulating real-gas effects
The Langley hypersonic CF4 tunnel is described focusing on the basic components, instrumentation, and operational capabilities. This tunnel is the only operational hypersonic facility which simulates an important aspect of dissociative real-gas phenomena associated with the reentry of blunt vehicles, i.e., the increase in density ratio across a normal shock or the decrease in the ratio of specific heats (gamma) that occurs within the shock layer of the vehicle. Particular attention is given to detailed pilot-pressure surveys for a new axisymmetric Mach 6 nozzle which were measured at the nozzle exit and downstream of the exit for reservoir pressures from 100 to 2000 psia and reservoir temperatures from 1100 to 1350 R.
Micol, John R.↗
Characterization of the NASA Langley Arc Heated Scramjet Test Facility Using NO PLIF
The nitric oxide planar laser-induced fluorescence (NO PLIF) imaging was used to characterize the air flow of the NASA Langley Arc Heated Scramjet Test Facility (AHSTF) configured with a Mach 6 nozzle. The arc raises the enthalpy of the test gas in AHSTF, producing nitric oxide. Nitric oxide persists as the temperature drops through the nozzle into the test section. NO PLIF was used to qualitatively visualize the flowfield at different experimental conditions, measure the temperature of the gas flow exiting the facility nozzle, and visualize the wave structure downstream of the nozzle at different operating conditions. Uniformity and repeatability of the nozzle flow were assessed. Expansion and compression waves on the free-jet shear layer as the nozzle flow expands into the test section were visualized. The main purpose of these experiments was to assess the uniformity of the NO in the freestream gas for planned experiments, in which NO PLIF will be used for qualitative fuel-mole-fraction sensitive imaging. The shot-to-shot fluctuations in the PLIF signal, caused by variations in the overall laser intensity as well as NO concentration and temperature variations in the flow was 20-25% of the mean signal, as determined by taking the standard deviation of a set of images obtained at constant conditions and dividing by the mean. The fluctuations within individual images, caused by laser sheet spatial variations as well as NO concentration and temperature variations in the flow, were about 28% of the mean in images, determined by taking standard deviation within individual images, dividing by the mean in the same image and averaged over the set of images. Applying an averaged laser sheet intensity correction reduced the within-image intensity fluctuations to about 10% suggesting that the NO concentration is uniform to within 10%. There was no significant difference in flow uniformity between the low and high enthalpy settings. While not strictly quantitative, the temperature maps show qualitative agreement with the computations of the flow.
Kidd, F. Gray, III↗
Computational and numerical analysis of hypersonic nozzle flows with comparisons to wind tunnel calibration data
Navier-Stokes (NS), parabolized NS codes, and classical method of characteristics prediction techniques are employed to compute hypersonic nozzle flowfields for the 15 in Mach 6 High Temperature Tunnel and the 16 in Mach 17 Nitrogen Tunnel, which are part of the Langley Research Center. The study focuses on defining the accuracy of these techniques by comparing the computational results to wind tunnel pitot pressure measurements conducted in the newly designed nozzle of the Mach 6 tunnel and in the original nozzle of the Mach 17 tunnel. The comparisons between predicted results and test section pitot surveys for the Mach 6 nozzle are in good agreement and show highly uniform flow over a range of reservoir pressures and temperatures.
Hackett, Charles M.↗
Mach 6 electroformed nickel nozzle refurbishment: FNAS investigation of ultra-smooth surfaces
The task objective has been to apply a coating of nickel-phosphorous alloy to a laminar flow wind tunnel nozzle by catalytic deposition and then polish and inspect the inside surface using optical device processes. The surface of the nozzle was coated with a nickel-phosphorous alloy of sufficient hardness and corrosion resistance to improve the durability. Due to plating defects that were clearly process related and not inherent, the final polished part was less than the desired quality. Surface finishing processes and lapping media were identified which produced a submicron surface finish on the interior plated surface. Defects apparently manifested by the first plating attempt were repaired using a small brush plating process demonstrating that individual small defects can be repaired. Measurement and analysis by profilometry demonstrated that quantitative control of the surface can be achieved.
Rood, Robert↗
1998 Calibration of the Mach 4.7 and Mach 6 Arc-Heated Scramjet Test Facility Nozzles
A calibration of the Arc-Heated Scramjet Test Facility (AHSTF) Mach 4.7 and Mach 6 nozzles was performed in 1998. For each nozzle, three different typical facility operating test points were selected for calibration. Each survey consisted of measurements, at 340 separate locations across the 11 inch square nozzle exit plane, of pitot pressure, static pressure, and total temperature. Measurement density was higher (4/inch) in the boundary layer near the nozzle wall than in the core nozzle flow (1/inch). The results generated for each of these calibration surveys were contour plots at the nozzle exit plane of the measured and calculated flow properties which completely defined the thermodynamic state of the nozzle exit flow. An area integration of the mass flux at the nozzle exit for each survey was compared to the AHSTF mass flow meter results to provide an indication of the overall quality of the calibration performed. The percent difference between the integrated nozzle exit mass flow and the flow meter ranged from 0.0 to 1.3 percent for the six surveys. Finally, a comparison of this 1998 calibration was made with the 1986 calibration. Differences of less than 10 percent were found within the nozzle core flow while in the boundary layer differences on the order of 20 percent were quite common.
Witte, David W.↗
Comparisons Between NO PLIF Imaging and CFD Simulations of Mixing Flowfields for High-Speed Fuel Injectors
The current work compares experimentally and computationally obtained nitric oxide (NO) planar laser-induced fluorescence (PLIF) images of the mixing flowfields for three types of high-speed fuel injectors: a strut, a ramp, and a rectangular flush-wall. These injection devices, which exhibited promising mixing performance at lower flight Mach numbers, are currently being studied as a part of the Enhanced Injection and Mixing Project (EIMP) at the NASA Langley Research Center. The EIMP aims to investigate scramjet fuel injection and mixing physics, and improve the understanding of underlying physical processes relevant to flight Mach numbers greater than eight. In the experiments, conducted in the NASA Langley Arc-Heated Scramjet Test Facility (AHSTF), the injectors are placed downstream of a Mach 6 facility nozzle, which simulates the high Mach number air flow at the entrance of a scramjet combustor. Helium is used as an inert substitute for hydrogen fuel. The PLIF is obtained by using a tunable laser to excite the NO, which is present in the AHSTF air as a direct result of arc-heating. Consequently, the absence of signal is an indication of pure helium (fuel). The PLIF images computed from the computational fluid dynamics (CFD) simulations are obtained by combining a fluorescence model for NO with the Reynolds-Averaged Simulation results carried out using the VULCAN-CFD solver to obtain a computational equivalent of the experimentally measured PLIF signal. The measured NO PLIF signal is mainly a function of NO concentration allowing for semi-quantitative comparisons between the CFD and the experiments. The PLIF signal intensity is also sensitive to pressure and temperature variations in the flow, allowing additional flow features to be identified and compared with the CFD. Good agreement between the PLIF and the CFD results provides increased confidence in the CFD simulations for investigations of injector performance.
Drozda, Tomasz, G.↗
Comparisons Between NO PLIF Imaging and CFD Simulations of Mixing Flowfields for High-Speed Fuel Injectors
The current work compares experimentally and computationally obtained nitric oxide (NO) planar laser induced fluorescence (PLIF) images of the mixing flowfields for three types of high-speed fuel injectors: a strut, a ramp, and a rectangular flushwall. These injection devices, which exhibited promising mixing performance at lower flight Mach numbers, are currently being studied as a part of the Enhanced Injection and Mixing Project (EIMP) at the NASA Langley Research Center. The EIMP aims to investigate scramjet fuel injection and mixing physics, and improve the understanding of underlying physical processes relevant to flight Mach numbers greater than eight. In the experiments, conducted in the NASA Langley Arc-Heated Scramjet Test Facility (AHSTF), the injectors are placed downstream of a Mach 6 facility nozzle, which simulates the high Mach number air flow at the entrance of a scramjet combustor. Helium is used as an inert substitute for hydrogen fuel. Both schlieren and PLIF techniques are applied to obtain mixing flowfield flow visualizations. The experimental PLIF is obtained by using a UV laser sheet to interrogate a plane of the flow by exciting fluorescence from the NO molecules, which are present in the AHSTF air. Consequently, the absence of signal in the resulting PLIF images is an indication of pure helium (fuel). The computational PLIF is obtained by applying a fluorescence model for NO to the results of the Reynolds-averaged simulations (RAS) of the mixing flow field carried out using the VULCAN-CFD solver. This approach is required because the PLIF signal is a nonlinear function of not only NO concentration, but also pressure, temperature, and the flow velocity. This complexity allows additional flow features to be identified and compared with those obtained from the computational fluid dynamics (CFD) simulations, however, such comparisons are only semiquantitative. Three-dimensional image reconstruction, similar to that used in magnetic resonance imaging, is also used to obtain images in the streamwise and spanwise planes from select cross-stream PLIF plane data. Synthetic schlieren is also computed from the RAS data. Good agreement between the experimental and computational results provides increased confidence in the CFD simulations for investigations of injector performance.
Drozda, Tomasz G.↗
Analysis of the Two-Level NO PLIF Model for Low-Temperature High-Speed Flow Applications
The current work compares experimentally obtained nitric oxide (NO) laser-induced fluorescence (LIF) spectra with the equivalent spectra obtained analytically. The experimental spectra are computed from captured images of fluorescence in a gas cell and from a laser sheet passing through the fuel-air mixing flowfield produced by a high-speed fuel injector. The fuel injector is a slender strut that is currently being studied as a part of the Enhanced Injection and Mixing Project (EIMP) at the NASA Langley Research Center. This injector is placed downstream of a Mach 6 facility nozzle, which simulates the high Mach number airflow at the entrance of a scramjet combustor, and injects helium, which is used as an inert substitute for hydrogen fuel. Experimental planar (P) LIF is obtained by using a UV laser to excite fluorescence from the NO molecules that are present in either a gas cell or the facility air used for the EIMP experiments. The experimental data are obtained for several segments of the NO fluorescence spectrum. The selected segments encompass LIF lines with rotational quantum numbers appropriate for low-to-moderate temperature flows similar to those corresponding to the nominal experimental flow conditions. The experimental LIF spectra are then evaluated from the data and compared with those obtained from the theoretical models. The theoretical spectra are obtained from LIFBASE and LINUS software, and from a simplified version of the two-level fluorescence model. The equivalent analytic PLIF images are also obtained by applying only the simplified model to the results of the Reynolds-averaged simulations (RAS) of the mixing flowfield. Good agreement between the experimental and theoretical results provides increased confidence in both the simplified LIF modeling and CFD simulations for further investigations of high-speed injector performance using this approach.
Drozda, Tomasz G.↗
Analysis of the Two-Level NO PLIF Model for Low-Temperature High-Speed Flow Applications
The current work compares experimentally obtained nitric oxide (NO) laser-induced fluorescence (LIF) spectra with the equivalent spectra obtained analytically. The experimental spectra are computed from captured images of fluorescence in a gas cell and from a laser sheet passing through the fuel-air mixing flowfield produced by a high-speed fuel injector. The fuel injector is a slender strut that is currently being studied as a part of the Enhanced Injection and Mixing Project (EIMP) at the NASA Langley Research Center. This injector is placed downstream of a Mach 6 facility nozzle, which simulates the high Mach number airflow at the entrance of a scramjet combustor, and injects helium, which is used as an inert substitute for hydrogen fuel. Experimental planar (P) LIF is obtained by using a UV laser to excite fluorescence from the NO molecules that are present in either a gas cell or the facility air used for the EIMP experiments. The experimental data are obtained for several segments of the NO fluorescence spectrum. The selected segments encompass LIF lines with rotational quantum numbers appropriate for low-to-moderate temperature flows similar to those corresponding to the nominal experimental flow conditions. The experimental LIF spectra are then evaluated from the data and compared with those obtained from the theoretical models. The theoretical spectra are obtained from LIFBASE and LINUS software, and from a simplified version of the two-level fluorescence model. The equivalent analytic PLIF images are also obtained by applying only the simplified model to the results of the Reynolds-averaged simulations (RAS) of the mixing flowfield. Good agreement between the experimental and theoretical results provides increased confidence in both the simplified LIF modeling and CFD simulations for further investigations of high-speed injector performance using this approach.
Tomasz G Drozda↗