Engineering topics
Schuster, David M.
Publications and source records attributed to Schuster, David M..
Investigation of Unsteady Pressure-Sensitive Paint (uPSP) and a Dynamic Loads Balance to Predict Launch Vehicle Buffet Environments
This NESC assessment examined the accuracy of estimating buffet loads on in-line launch vehicles without booster attachments using sparse unsteady pressure measurements. The buffet loads computed using sparse sensor data were compared with estimates derived using measurements with much higher spatial resolution. The current method for estimating launch vehicle buffet loads is through wind tunnel testing of models with approximately 400 unsteady pressure transducers. Even with this relatively large number of sensors, the coverage can be insufficient to provide reliable integrated unsteady loads on vehicles. In general, sparse sensor spacing requires the use of coherence-length-based corrections in the azimuthal and axial directions to integrate the unsteady pressures and obtain reasonable estimates of the buffet loads. Coherence corrections have been used to estimate buffet loads for a variety of launch vehicles with the assumption methodology results in reasonably conservative loads. For the Space Launch System (SLS), the first estimates of buffet loads exceeded the limits of the vehicle structure, so additional tests with higher sensor density were conducted to better define the buffet loads and possibly avoid expensive modifications to the vehicle design. Without the additional tests and improvements to the coherence-length analysis methods, there would have been significant impacts to the vehicle weight, cost, and schedule. If the load estimates turn out to be too low, there is significant risk of structural failure of the vehicle. This assessment used a combination of unsteady pressure-sensitive paint (uPSP), unsteady pressure transducers, and a dynamic force and moment balance to investigate the integration schemes used with limited unsteady pressure data by comparing them with direct integration of extremely dense fluctuating pressure measurements. An outfall of the assessment was to evaluate the potential of using the emerging uPSP technique in a production test environment for future launch vehicles. The results show that modifications to the current technique can improve the accuracy of buffet estimates. More importantly, the uPSP worked remarkably well and, with improvements to the frequency response, sensitivity, and productivity, will provide an enhanced method for measuring wind tunnel buffet forcing functions (BFFs).
Infrared Observations of the Orion Capsule During EFT-1 Hypersonic Reentry
High-resolution infrared observations of the Orion capsule during its atmospheric reentry on December 5, 2015 were made from a US Navy NP-3D. This aircraft, equipped with a long-range optical sensor system, tracked the capsule from Mach 10 to 7 from a distance of approximately 60 nmi. Global surface temperatures of the capsule's thermal heatshield were derived from near infrared intensity measurements. The global surface temperature measurements complemented onboard instrumentation and were invaluable to the interpretation of the in-depth thermocouple measurements which rely on inverse heat transfer methods and material response codes to infer the desired surface temperature from the sub-surface measurements. The full paper will address the motivations behind the NASA Engineering Safety Center sponsored observation and highlight premission planning processes with an emphasis on aircraft placement, optimal instrument configuration and sensor calibrations. Critical aspects of mission operations coordinated from the NASA Johnson Spaceflight Center and integration with the JSC Flight Test Management Office will be discussed. A summary of the imagery that was obtained and processed to global surface temperature will be presented. At the capsule's point of closest approach relative to the imaging system, the spatial resolution was estimated to be approximately 15-inches per pixel and was sufficient to identify localized temperature increases associated with compression pad support hardware on the heatshield. The full paper will discuss the synergy of the quantitative imagery derived temperature maps with in-situ thermocouple measurements. Comparison of limited onboard surface thermocouple data to the image derived surface temperature will be presented. The two complimentary measurements serve as an example of the effective leveraging of resources to advance the understanding of high Mach number environments associated with an ablated heatshield and provide unique data for the validation of design tools and numerical flight simulation techniques. Collaborative opportunities and technology investments in support of planned observations of NASA's next Orion flight test in 2018 will be explored in the full manuscript.
Remote Imaging of Exploration Flight Test-1 (EFT-1) Entry Heating Risk Reduction
A Measure of Performance (MOP) identified with an Exploration Flight Test-1 (EFT-1) Multi- Purpose Crew Vehicle (MPCV) Program Flight Test Objective (FTO) (OFT1.091) specified an observation during reentry though external ground-based or airborne assets with thermal detection capabilities. The objective of this FTO was to be met with onboard Developmental Flight Instrumentation (DFI), but the MOP for external observation was intended to provide complementary quantitative data and serve as a risk reduction in the event of anomalous DFI behavior (or failure). Mr. Gavin Mendeck, the Entry, Descent, and Landing (EDL) Phase Engineer for the MPCV Program (Vehicle Integration Office/Systems & Mission Integration) requested a risk-reduction assessment from the NASA Engineering and Safety Center (NESC) to determine whether quantitative imagery could be obtained from remote aerial assets to support the external observation MOP. If so, then a viable path forward was to be determined, risks identified, and an observation pursued. If not, then the MOP for external observation was to be eliminated.
Time-Accurate Unsteady Pressure Loads Simulated for the Space Launch System at Wind Tunnel Conditions
A transonic flow field about a Space Launch System (SLS) configuration was simulated with the Fully Unstructured Three-Dimensional (FUN3D) computational fluid dynamics (CFD) code at wind tunnel conditions. Unsteady, time-accurate computations were performed using second-order Delayed Detached Eddy Simulation (DDES) for up to 1.5 physical seconds. The surface pressure time history was collected at 619 locations, 169 of which matched locations on a 2.5 percent wind tunnel model that was tested in the 11 ft. x 11 ft. test section of the NASA Ames Research Center's Unitary Plan Wind Tunnel. Comparisons between computation and experiment showed that the peak surface pressure RMS level occurs behind the forward attach hardware, and good agreement for frequency and power was obtained in this region. Computational domain, grid resolution, and time step sensitivity studies were performed. These included an investigation of pseudo-time sub-iteration convergence. Using these sensitivity studies and experimental data comparisons, a set of best practices to date have been established for FUN3D simulations for SLS launch vehicle analysis. To the author's knowledge, this is the first time DDES has been used in a systematic approach and establish simulation time needed, to analyze unsteady pressure loads on a space launch vehicle such as the NASA SLS.
Plans and Example Results for the 2nd AIAA Aeroelastic Prediction Workshop
This paper summarizes the plans for the second AIAA Aeroelastic Prediction Workshop. The workshop is designed to assess the state-of-the-art of computational methods for predicting unsteady flow fields and aeroelastic response. The goals are to provide an impartial forum to evaluate the effectiveness of existing computer codes and modeling techniques, and to identify computational and experimental areas needing additional research and development. This paper provides guidelines and instructions for participants including the computational aerodynamic model, the structural dynamic properties, the experimental comparison data and the expected output data from simulations. The Benchmark Supercritical Wing (BSCW) has been chosen as the configuration for this workshop. The analyses to be performed will include aeroelastic flutter solutions of the wing mounted on a pitch-and-plunge apparatus.
Time Accurate Unsteady Pressure Loads Simulated for the Space Launch System at a Wind Tunnel Condition
Using the Fully Unstructured Three-Dimensional (FUN3D) computational fluid dynamics code, an unsteady, time-accurate flow field about a Space Launch System configuration was simulated at a transonic wind tunnel condition (Mach = 0.9). Delayed detached eddy simulation combined with Reynolds Averaged Naiver-Stokes and a Spallart-Almaras turbulence model were employed for the simulation. Second order accurate time evolution scheme was used to simulate the flow field, with a minimum of 0.2 seconds of simulated time to as much as 1.4 seconds. Data was collected at 480 pressure taps at locations, 139 of which matched a 3% wind tunnel model, tested in the Transonic Dynamic Tunnel (TDT) facility at NASA Langley Research Center. Comparisons between computation and experiment showed agreement within 5% in terms of location for peak RMS levels, and 20% for frequency and magnitude of power spectral densities. Grid resolution and time step sensitivity studies were performed to identify methods for improved accuracy comparisons to wind tunnel data. With limited computational resources, accurate trends for reduced vibratory loads on the vehicle were observed. Exploratory methods such as determining minimized computed errors based on CFL number and sub-iterations, as well as evaluating frequency content of the unsteady pressures and evaluation of oscillatory shock structures were used in this study to enhance computational efficiency and solution accuracy. These techniques enabled development of a set of best practices, for the evaluation of future flight vehicle designs in terms of vibratory loads.
Orion Multi-Purpose Crew Vehicle (MPCV) Capsule Parachute Assembly System (CPAS) Wake Deficit Wind Tunnel Testing
During descent after re-entry into the Earth's atmosphere, the Orion CM deploys its drogue parachutes at approximately Mach 0.7. Accurately predicting the dynamic pressure experienced by the drogue parachutes at deployment is critical to properly designing the parachutes. This NASA Engineering and Safety Center assessment was designed to provide a complete set of flowfield measurements on and around an idealized Orion Crew Module shape with the most appropriate wind tunnel simulation of the Orion flight conditions prior to parachute deployment. This document contains the details of testing and the outcome of the assessment.
Overview of the Aeroelastic Prediction Workshop
The AIAA Aeroelastic Prediction Workshop (AePW) was held in April, 2012, bringing together communities of aeroelasticians and computational fluid dynamicists. The objective in conducting this workshop on aeroelastic prediction was to assess state-of-the-art computational aeroelasticity methods as practical tools for the prediction of static and dynamic aeroelastic phenomena. No comprehensive aeroelastic benchmarking validation standard currently exists, greatly hindering validation and state-of-the-art assessment objectives. The workshop was a step towards assessing the state of the art in computational aeroelasticity. This was an opportunity to discuss and evaluate the effectiveness of existing computer codes and modeling techniques for unsteady flow, and to identify computational and experimental areas needing additional research and development. Three configurations served as the basis for the workshop, providing different levels of geometric and flow field complexity. All cases considered involved supercritical airfoils at transonic conditions. The flow fields contained oscillating shocks and in some cases, regions of separation. The computational tools principally employed Reynolds-Averaged Navier Stokes solutions. The successes and failures of the computations and the experiments are examined in this paper.
Overview of the Aeroelastic Prediction Workshop
The Aeroelastic Prediction Workshop brought together an international community of computational fluid dynamicists as a step in defining the state of the art in computational aeroelasticity. This workshop's technical focus was prediction of unsteady pressure distributions resulting from forced motion, benchmarking the results first using unforced system data. The most challenging aspects of the physics were identified as capturing oscillatory shock behavior, dynamic shock-induced separated flow and tunnel wall boundary layer influences. The majority of the participants used unsteady Reynolds-averaged Navier Stokes codes. These codes were exercised at transonic Mach numbers for three configurations and comparisons were made with existing experimental data. Substantial variations were observed among the computational solutions as well as differences relative to the experimental data. Contributing issues to these differences include wall effects and wall modeling, non-standardized convergence criteria, inclusion of static aeroelastic deflection, methodology for oscillatory solutions, post-processing methods. Contributing issues pertaining principally to the experimental data sets include the position of the model relative to the tunnel wall, splitter plate size, wind tunnel expansion slot configuration, spacing and location of pressure instrumentation, and data processing methods.
Lessons Learned in the Selection and Development of Test Cases for the Aeroelastic Prediction Workshop: Rectangular Supercritical Wing
The Aeroelastic Prediction Workshop brought together an international community of computational fluid dynamicists as a step in defining the state of the art in computational aeroelasticity. The Rectangular Supercritical Wing (RSW) was chosen as the first configuration to study due to its geometric simplicity, perceived simple flow field at transonic conditions and availability of an experimental data set containing forced oscillation response data. Six teams performed analyses of the RSW; they used Reynolds-Averaged Navier-Stokes flow solvers exercised assuming that the wing had a rigid structure. Both steady-state and forced oscillation computations were performed by each team. The results of these calculations were compared with each other and with the experimental data. The steady-state results from the computations capture many of the flow features of a classical supercritical airfoil pressure distribution. The most dominant feature of the oscillatory results is the upper surface shock dynamics. Substantial variations were observed among the computational solutions as well as differences relative to the experimental data. Contributing issues to these differences include substantial wind tunnel wall effects and diverse choices in the analysis parameters.
Analysis of Test Case Computations and Experiments for the First Aeroelastic Prediction Workshop
This paper compares computational and experimental data from the Aeroelastic Prediction Workshop (AePW) held in April 2012. This workshop was designed as a series of technical interchange meetings to assess the state of the art of computational methods for predicting unsteady flowfields and static and dynamic aeroelastic response. The goals are to provide an impartial forum to evaluate the effectiveness of existing computer codes and modeling techniques to simulate aeroelastic problems and to identify computational and experimental areas needing additional research and development. Three subject configurations were chosen from existing wind-tunnel data sets where there is pertinent experimental data available for comparison. Participant researchers analyzed one or more of the subject configurations, and results from all of these computations were compared at the workshop.
A Summary of Data and Findings from the First Aeroelastic Prediction Workshop
This paper summarizes data and findings from the first Aeroelastic Prediction Workshop (AePW) held in April, 2012. The workshop has been designed as a series of technical interchange meetings to assess the state of the art of computational methods for predicting unsteady flowfields and static and dynamic aeroelastic response. The goals are to provide an impartial forum to evaluate the effectiveness of existing computer codes and modeling techniques to simulate aeroelastic problems, and to identify computational and experimental areas needing additional research and development. For this initial workshop, three subject configurations have been chosen from existing wind tunnel data sets where there is pertinent experimental data available for comparison. Participant researchers analyzed one or more of the subject configurations and results from all of these computations were compared at the workshop. Keywords: Unsteady Aerodynamics, Aeroelasticity, Computational Fluid Dynamics, Transonic Flow, Separated Flow.
Reacting Multi-Species Gas Capability for USM3D Flow Solver
The USM3D Navier-Stokes flow solver contributed heavily to the NASA Constellation Project (CxP) as a highly productive computational tool for generating the aerodynamic databases for the Ares I and V launch vehicles and Orion launch abort vehicle (LAV). USM3D is currently limited to ideal-gas flows, which are not adequate for modeling the chemistry or temperature effects of hot-gas jet flows. This task was initiated to create an efficient implementation of multi-species gas and equilibrium chemistry into the USM3D code to improve its predictive capabilities for hot jet impingement effects. The goal of this NASA Engineering and Safety Center (NESC) assessment was to implement and validate a simulation capability to handle real-gas effects in the USM3D code. This document contains the outcome of the NESC assessment.
Multi-functional annular fairing for coupling launch abort motor to space vehicle
An annular fairing having aerodynamic, thermal, structural and acoustic attributes couples a launch abort motor to a space vehicle having a payload of concern mounted on top of a rocket propulsion system. A first end of the annular fairing is fixedly attached to the launch abort motor while a second end of the annular fairing is attached in a releasable fashion to an aft region of the payload. The annular fairing increases in diameter between its first and second ends.
Grid Fin Stabilization of the Orion Launch Abort Vehicle
Wind tunnel tests were conducted by Nielsen Engineering & Research (NEAR) and Rose Engineering & Research (REAR) in conjunction with the NASA Engineering & Safety Center (NESC) on a 6%-scale model of the Orion launch abort vehicle (LAV) configured with four grid fins mounted near the base of the vehicle. The objectives of these tests were to 1) quantify LAV stability augmentation provided by the grid fins from subsonic through supersonic Mach numbers, 2) assess the benefits of swept grid fins versus unswept grid fins on the LAV, 3) determine the effects of the LAV abort motors on grid fin aerodynamics, and 4) generate an aerodynamic database for use in the future application of grid fins to small length-to-diameter ratio vehicles similar to the LAV. The tests were conducted in NASA Ames Research Center's 11x11-foot transonic wind tunnel from Mach 0.5 through Mach 1.3 and in their 9x7-foot supersonic wind tunnel from Mach 1.6 through Mach 2.5. Force- and moment-coefficient data were collected for the complete vehicle and for each individual grid fin as a function of angle of attack and sideslip angle. Tests were conducted with both swept and unswept grid fins with the simulated abort motors (cold jets) off and on. The swept grid fins were designed with a 22.5deg aft sweep angle for both the frame and the internal lattice so that the frontal projection of the swept fins was the same as for the unswept fins. Data from these tests indicate that both unswept and swept grid fins provide significant improvements in pitch stability as compared to the baseline vehicle over the Mach number range investigated. The swept fins typically provide improved stability as compared to the unswept fins, but the performance gap diminished as Mach number was increased. The aerodynamic performance of the fins was not observed to degrade when the abort motors were turned on. Results from these tests indicate that grid fins can be a robust solution for stabilizing the Orion LAV over a wide range of operating conditions.
Plans for Aeroelastic Prediction Workshop
This paper summarizes the plans for the first Aeroelastic Prediction Workshop. The workshop is designed to assess the state of the art of computational methods for predicting unsteady flow fields and aeroelastic response. The goals are to provide an impartial forum to evaluate the effectiveness of existing computer codes and modeling techniques, and to identify computational and experimental areas needing additional research and development. Three subject configurations have been chosen from existing wind tunnel data sets where there is pertinent experimental data available for comparison. For each case chosen, the wind tunnel testing was conducted using forced oscillation of the model at specified frequencies
Modeling, Analysis and Simulation Approaches Used in Development of the National Aeronautics and Space Administration Max Launch Abort System
The National Aeronautics and Space Administration (NASA) Engineering and Safety Center was chartered to develop an alternate launch abort system (LAS) as risk mitigation for the Orion Project. Its successful flight test provided data for the design of future LAS vehicles. Design of the flight test vehicle (FTV) and pad abort trajectory relied heavily on modeling and simulation including computational fluid dynamics for vehicle aero modeling, 6-degree-of-freedom kinematics models for flight trajectory modeling, and 3-degree-of-freedom kinematics models for parachute force modeling. This paper highlights the simulation techniques and the interaction between the aerodynamics, flight mechanics, and aerodynamic decelerator disciplines during development of the Max Launch Abort System FTV.