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Engineering and fabrication cost considerations for cryogenic wind tunnel models

Design and fabrication cost drivers for cryogenic transonic wind tunnel models are defined. The major cost factors for wind tunnel models are model complexity, tolerances, surface finishes, materials, material validation, and model inspection. The cryogenic temperatures require the use of materials with relatively high fracture toughness but at the same time high strength. Some of these materials are very difficult to machine, requiring extensive machine hours which can add significantly to the manufacturing costs. Some additional engineering costs are incurred to certify the materials through mechanical tests and nondestructive evaluation techniques, which are not normally required with conventional models. When instrumentation such as accelerometers and electronically scanned pressure modules is required, temperature control of these devices needs to be incorporated into the design, which requires added effort. Additional thermal analyses and subsystem tests may be necessary, which also adds to the design costs. The largest driver to the design costs is potentially the additional static and dynamic analyses required to insure structural integrity of the model and support system.

Boykin, R. M., Jr.↗

Supersonic Wind Tunnels (Latest Citations from the Aerospace Database)

The bibliography contains citations concerning the design, construction, operation, performance, and use of supersonic wind tunnels. References cover the design of flow nozzles, diffusers, test sections, and ejectors for tunnels driven by compressed air, high-pressure gases, or cryogenic liquids. Methods for flow calibration, boundary layer control, local and freestream turbulence reduction, and force measurement are discussed. Instrusive and non-intrusive instrumentation, sources of measurement error, and measurement corrections are also covered. The citations also include the testing of inlets, nozzles, airfoils, and other components of aerospace vehicles that must operate supersonically. Comprehensive coverage of wind tunnel force balancing systems, and blowdown and supersonic wind tunnels are covered in separate bibliographies.(Contains 50-250 citations and includes a subject term index and title list.)

WIND TUNNELS↗

Initial Investigation of Cryogenic Wind Tunnel Model Filler Materials

Filler materials are used for surface flaws, instrumentation grooves, and fastener holes in wind tunnel models. More stringent surface quality requirements and the more demanding test environment encountered by cryogenic wind tunnels eliminate filler materials such as polyester resins, plaster, and waxes used on conventional wind tunnel models. To provide a material data base for cryogenic models, various filler materials are investigated. Surface quality requirements and test temperature extremes require matching of coefficients of thermal expansion or interfacing materials. Microstrain versus temperature curves are generated for several candidate filler materials for comparison with cryogenically acceptable materials. Matches have been achieved for aluminum alloys and austenitic steels. Simulated model surfaces are filled with candidate filler materials to determine finishing characteristics, adhesion and stability when subjected to cryogenic cycling. Filler material systems are identified which meet requirements for usage with aluminum model components.

Firth, G. C.↗

Introduction to cryogenic wind tunnels

The background to the evolution of the cryogenic wind tunnel is outlined, with particular reference to the late 60's/early 70's when efforts were begun to re-equip with larger wind tunnels. The problems of providing full scale Reynolds numbers in transonic testing were proving particularly intractible, when the notion of satisfying the needs with the cryogenic tunnel was proposed, and then adopted. The principles and advantages of the cryogenic tunnel are outlined, along with guidance on the coolant needs when this is liquid nitrogen, and with a note on energy recovery. Operational features of the tunnels are introduced with reference to a small low speed tunnel. Finally the outstanding contributions are highlighted of the 0.3-Meter Transonic Cryogenic Tunnel (TCT) at NASA Langley Research Center, and its personnel, to the furtherance of knowledge and confidence in the concept.

Goodyer, M. J.↗

Persistence Characteristics of Wind-Tunnel Pressure Signatures From Two Similar Models

Pressure signatures generated by two sonic-boom wind-tunnel models and measured at Mach 2 are presented, analyzed, and discussed. The two wind-tunnel models differed in length and span by a factor of fourteen, but were similar in wing-body planform shape. The geometry of the larger model had been low-boom tailored to generate a flat top ground pressure signature, and the nacelles-off pressure signatures from this model became more flattop in shape as the model-probe separation distances increased from 0.94 to 4.4 span lengths. The geometry of the smaller model had not been low-boom tailored, yet its measured pressure signatures had non-N-wave shapes that persisted as model-probe separation distances increased from 26.0 to 104.2 span lengths. Since the overall planforms of the two wind-tunnel models were so similar, it was concluded that the shape-persistence trends in the pressure signatures of the smaller, non-low-boom tailored model would also be present at very large distances in the pressure signatures of the larger, low-boom-tailored model.

Mack, Robert J.↗

Aeroelastic Deformation: Adaptation of Wind Tunnel Measurement Concepts to Full-Scale Vehicle Flight Testing

The adaptation of a proven wind tunnel test technique, known as Videogrammetry, to flight testing of full-scale vehicles is presented. A description is presented of the technique used at NASA's Dryden Flight Research Center for the measurement of the change in wing twist and deflection of an F/A-18 research aircraft as a function of both time and aerodynamic load. Requirements for in-flight measurements are compared and contrasted with those for wind tunnel testing. The methodology for the flight-testing technique and differences compared to wind tunnel testing are given. Measurement and operational comparisons to an older in-flight system known as the Flight Deflection Measurement System (FDMS) are presented.

Burner, Alpheus W.↗

Aeroelastic Deformation: Adaptation of Wind Tunnel Measurement Concepts to Full-Scale Vehicle Flight Testing

The adaptation of a proven wind tunnel test technique, known as Videogrammetry, to flight testing of full-scale vehicles is presented. A description is presented of the technique used at NASA's Dryden Flight Research Center for the measurement of the change in wing twist and deflection of an F/A-18 research aircraft as a function of both time and aerodynamic load. Requirements for in-flight measurements are compared and contrasted with those for wind tunnel testing. The methodology for the flight-testing technique and differences compared to wind tunnel testing are given. Measurement and operational comparisons to an older in-flight system known as the Flight Deflection Measurement System (FDMS) are presented.

Burner, Alpheus W.↗

Modification of the Ames 40- by 80-foot wind tunnel for component acoustic testing for the second generation supersonic transport

The development of a large-scale anechoic test facility where large models of engine/airframe/high-lift systems can be tested for both improved noise reduction and minimum performance degradation is described. The facility development is part of the effort to investigate economically viable methods of reducing second generation high speed civil transport noise during takeoff and climb-out that is now under way in the United States. This new capability will be achieved through acoustic modifications of NASA's second largest subsonic wind tunnel: the 40-by 80-Foot Wind Tunnel at the NASA Ames Research Center. Three major items are addressed in the design of this large anechoic and quiet wind tunnel: a new deep (42 inch (107 cm)) test section liner, expansion of the wind tunnel drive operating envelope at low rpm to reduce background noise, and other promising methods of improving signal-to-noise levels of inflow microphones. Current testing plans supporting the U.S. high speed civil transport program are also outlined.

Schmitz, F. H.↗

Cryogenic wind tunnels: Unique capabilities for the aerodynamicist

The cryogenic wind-tunnel concept as a practical means for improving ground simulation of transonic flight conditions. The Langley 1/3-meter transonic cryogenic tunnel is operational, and the design of a cryogenic National Transonic Facility is undertaken. A review of some of the unique capabilities of cryogenic wind tunnels is presented. In particular, the advantages of having independent control of tunnel Mach number, total pressure, and total temperature are highlighted. This separate control over the three tunnel parameters will open new frontiers in Mach number, Reynolds number, aeroelastic, and model-tunnel interaction studies.

Hall, R. M.↗

Comparison of Surface Pressure Fluctuations from Flight and Wind Tunnel Tests on the Orion Multi-Purpose Crew Vehicle

Transonic and supersonic wind-tunnel test of scaled-models are used to predict the surface pressure fluctuations on aerospace vehicles. An outstanding question is how good are such tests? The present paper attempts to answer this question for the Multi-Purpose Crew Vehicle by comparing data from the Ascent Abort-2 (AA2) flight test with those measured in two different scaled-model wind tunnel tests (WTT) 51AS and 134AS. A sensor by sensor and a Mach by Mach comparisons of spectra of surface pressure fluctuations are presented for nominal ascent part of flight. Spectra measured over a large part of the vehicle surface were found to be dominated by the wake vortices shed from the four Abort Motor nozzles situated on the upper part of the Launch Abort System. It was found that the shapes of the scaled-up spectra from WTTs were very close to those measured in the flight, but the levels, for the most part, were found to be lower than the flight data. The highest differences were from the regions of complex flows where wakes from the adjacent nozzles interacted with the free-stream flow. There the WTT predicted levels were consistently 2dB to 6dB lower than the flight data, across all spectral bands. Another region of significant under-prediction was the local separated flow region at the Fillet-Ogive junction. The accuracy of the sharp spectral peaks from regions along a nozzle axis was found to be dependent on the fidelity of the model. The model in the 51AS WTT used a simplified contour, which resulted in a large under prediction of the spectral peak by 1dB to 10dB. A limited number of data from 134AS, where the model accurately captured all features of the nozzles of the flight vehicle, however; showed that the under prediction was lower: 1-2dB. The fluctuation spectra on the large protuberance of the Umbilical Cover was found to be reasonably well-predicted by 134AS WTT, which meticulously reproduced a scaled-down shape of this protuberance. Such information will help to determine the margins to be applied to wind-tunnel data to create flight environments.

MPCV↗

Validation of a Compact Isokinetic Total Water Content Probe for Wind Tunnel Characterization at NASA Glenn Icing Research Tunnel and at NRC Ice Crystal Tunnel

A new compact isokinetic probe to measure total water content in a wind tunnel environment has been developed. The probe has been previously tested under altitude conditions. This paper presents a comprehensive validation of the probe under a range of liquid water conditions at sea level in the NASA Glenn Icing Research Tunnel and with ice crystals at sea level at the NRC wind tunnel. The compact isokinetic probe is compared to tunnel calibrations and other probes.

meterological instruments↗

Correlation of the Drag Characteristics of a Typical Pursuit Airplane Obtained from High-Speed Wind-Tunnel and Flight Tests

In order to obtain a correlation of drag data from wind-tunnel and flight tests at high Mach numbers, a typical pursuit airplane, with the propeller removed, was tested in flight at Mach numbers up to 0.755, and the results were compared with wind-tunnel tests of a 1/3-scale model of the airplane. The tests results show that the drag characteristics of the test airplane can be predicted with satisfactory accuracy from tests in the Ames 16-foot high-speed wind tunnel of the Ames Aeronautical Laboratory at both high and low Mach numbers. It is considered that this result is not unique with the airplane.

Nissen, James M↗

Institutional Schlieren: A Production-Level Wind Tunnel Test Measurement

The following details recent efforts undertaken at the NASA Ames Unitary Plan Wind Tunnel to design and deploy an advanced, institutional, production-level data system for the classical Schlieren-shadowgraph technique. Motivation for the selection of individual system components is discussed along with a software methodology that combines image acquisition and processing into a production-level wind tunnel test measurement. In general terms, a production-level measurement refers to any data system that is seamlessly integrated into the primary wind tunnel data system, and whose data products are available real-time (e.g. force and moment, pressure, temperature data). The advantage of integrating a measurement in such a manner is an immediate increase in data product efficiency, productivity, reliability, and quality. Coupled with these benefits and leveraging recent advancements in high-speed imaging and image processing, automated, synchronized, time-resolved Schlieren-shadowgraph imaging for dynamic flow phenomena is now a reality. This makes possible the synthesis of dynamic off-body imaging with unsteady on-body measurements to produce a uniquely descriptive data product invaluable to the modern researcher.

Shadowgraph↗

Wind tunnel investigation of vortex flows on F/A-18 configuration at subsonic through transonic speed

A wind tunnel experiment was conducted in the David Taylor Research Center 7- by 10-Foot Transonic Tunnel of the wing leading-edge extension (LEX) and forebody vortex flows at subsonic and transonic speeds about a 0.06-scale model of the F/A-18. The primary goal was to improve the understanding and control of the vortical flows, including the phenomena of vortex breakdown and vortex interactions with the vertical tails. Laser vapor screen flow visualizations, LEX, and forebody surface static pressures, and six-component forces and moments were obtained at angles of attack of 10 to 50 degrees, free-stream Mach numbers of 0.20 to 0.90, and Reynolds numbers based on the wing mean aerodynamic chord of 0.96 x 10(exp 6) to 1.75 x 10(exp 6). The wind tunnel results were correlated with in-flight flow visualizations and handling qualities trends obtained by NASA using an F-18 High-Alpha Research Vehicle (HARV) and by the Navy and McDonnell Douglas on F-18 aircraft with LEX fences added to improve the vertical tail buffet environment. Key issues that were addressed include the sensitivity of the vortical flows to the Reynolds number and Mach number; the reduced vertical tail excitation, and the corresponding flow mechanism, in the presence of the LEX fence; the repeatability of data obtained during high angle-of-attack wind tunnel testing of F-18 models; the effects of particle seeding for flow visualization on the quantitative model measurements; and the interpretation of off-body flow visualizations obtained using different illumination and particle seeding techniques.

Erickson, Gary E.↗

Dynamic response tests of inertial and optical wind-tunnel model attitude measurement devices

Results are presented for an experimental study of the response of inertial and optical wind-tunnel model attitude measurement systems in a wind-off simulated dynamic environment. This study is part of an ongoing activity at the NASA Langley Research Center to develop high accuracy, advanced model attitude measurement systems that can be used in a dynamic wind-tunnel environment. This activity was prompted by the inertial model attitude sensor response observed during high levels of model vibration which results in a model attitude measurement bias error. Significant bias errors in model attitude measurement were found for the measurement using the inertial device during wind-off dynamic testing of a model system. The amount of bias present during wind-tunnel tests will depend on the amplitudes of the model dynamic response and the modal characteristics of the model system. Correction models are presented that predict the vibration-induced bias errors to a high degree of accuracy for the vibration modes characterized in the simulated dynamic environment. The optical system results were uncorrupted by model vibration in the laboratory setup.

Buehrle, R. D.↗

Drive Motor Improved for 8- by 6-Foot Supersonic Wind Tunnel/9- by 15-Foot Low-Speed Wind Tunnel Complex

An operational change made recently in the drive motor system for the 8- by 6-Foot Supersonic Wind Tunnel (8x6 SWT)/9- by 15-Foot Low-Speed Wind Tunnel (9x15 LSWT) complex resulted in dramatic power savings and expanded operating range. The 8x6 SWT/9x15 LSWT complex offers a unique combination of wind tunnel conditions for both high- and low-speed testing. Prior to the work discussed in this article, the 8- by 6-ft test section offered airflows ranging from Mach 0.36 to 2.0. Subsonic testing was done in the 9-ft high, 15-ft wide test area in the return leg of the facility. The air speed in this test section can range from 0 to 175 mph (Mach 0.23). In the past, we varied the air speed by using a combination of the compressor speed and the position of the tunnel flow-control doors. When very slow speeds were required in the 9x15 LSWT, these large tunnel flow control doors might be very nearly full open, bleeding off large quantities of air, even with the drive system operating at its previous minimum speed of about 510 rpm. Power drawn during this mode of operation varied between 15 and 18 MW/hr, but clearly much of this power was not being used to provide air that would be used for testing in the test section. The air exiting these large doors represented wasted power. Early this year, the facility's tunnel drive system was run on one motor instead of three to see if lower drive speeds could be achieved that would, in turn, result in large power savings because unnecessary air would not be blown out of the flow-control doors unnecessarily. In addition, if the drive could be run slower, then slower speeds would also be possible in the 8x6 SWT test section as an added benefit. Results of the first tests performed early last year showed that in fact the drive, when operating on only one motor, actually reached a steady-state speed of only 337 rpm and drew an amazingly small 6 MW/hr of electrical power. During daytime operation of the drive, this meant that it would be possible to save as much as 10 MW/hr, or nearly $600 per hour of operation, for many of the 9x15 LSWT's testing regimes. An added benefit of this power-saving venture was that since the 8x6 SWT and 9x15 LSWT are indeed on a common loop, if the compressor is slowed down to benefit the 9x15 LSWT, then the air moving through the 8x6 SWT is also moving slower than ever before. In fact, testing has proven that the 8x6 SWT can now achieve Mach 0.25, whereas its previous lower limit was Mach 0.36. This added benefit has attracted additional customers

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