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NASA NTRSDate not supplied

Atmospheric Boundary-Layer and Flutter Computations Using CFD Model of the Transonic Dynamics Tunnel

This paper presents two Computational Fluid Dynamics (CFD) models of the flow in the NASA Langley Research Center Transonic Dynamics Tunnel (TDT). The TDT is a continuous-flow, closed circuit wind tunnel with a 16- by 16-foot slotted test section with cropped corners. The tunnel was originally built as the 19-ft Pressure Tunnel in 1938, but it was converted to the current transonic tunnel in the 1950s, with capabilities to use either air or heavy gas as the test medium. The first computational model describes the generation of an atmospheric-boundary-layer (ABL) profile inside the tunnel. An ABL, which includes both a wind profile and turbulence content, is one of the aerodynamic characteristics affecting the occurrence of wind-induced oscillations for a launch vehicle sitting on a pad. The challenging part of this analysis was modeling the turbulent flow inside the tunnel. This is due to the special ABL-generating hardware that was installed at the entrance of the TDT test section in order to change the downstream velocity profile and to introduce velocity fluctuations into the flow. The second CFD model builds on the computational aeroelastic results that were generated in support of the second Aeroelastic Prediction Workshop (AePW) for the NASA Benchmark Supercritical Wing (BSCW) configuration. During the AePW, the wing-only configuration (classical free-air model) was analyzed. In the current study, the flutter computations were conducted on the configuration as it was mounted in the TDT during the experiment. This includes the wing attached to the splitter plate that was attached to the wind-tunnel walls. The preliminary results show that the wind-tunnel walls marginally affect flutter prediction.

Pawel Chwalowski↗
NASA NTRS2021

AIAA Ascend 2021 Conference On Demand Manufacturing of Electronics Panel Abstract

1. Session Proposal o Session Title NASA’s In Space Manufacturing and the On Demand Manufacturing of Electronics o Session Topic Primary -- Space Logistics, Autonomy, and Robotics; Secondary – Transformative Research and Technologies o Session Format: Panel Discussion. o Requested Session Duration: 60 minutes o Short Session Description: The goal of NASA’s On Demand Manufacturing of Electronics project is to develop and demonstrate the feasibility of a low-gravity, on-demand manufacturing system for flexible hybrid electronic devices on the International Space Station. This panel will feature several key collaborators and team members from the commercial sector, academia, and internal to NASA, each of which are contributing an unique and vital role to the design and implementation of this new technology system. o Extended Session Description (Please describe in detail the activity proposed, including how you intend to use the requested session duration. This session description will be provided to the reviewers for consideration and will not be displayed in the online agenda.): The session will be moderated by Curtis Hill, the Project Lead for the On Demand Manufacturing of Electronics (ODME), and he will start by giving a brief introduction to the ODME project which is working to produce a demo system for the manufacturing of electronic devices on the International Space Station. Panelists consisting of collaborators and team members to the ODME project will then give a brief (~5 min) introduction highlighting their contributions to the project, followed by time for Q&A from the audience. The panel will consist of: 1. Kenneth Church, nScrypt. nScrypt is a leader in multi-material printing with a modular system that incorporates a direct write thick film print head, a polymer fused filament fabrication print head, a laser sintering attachment, a drill head attachment for milling, and a pick and place. The system can print a layer and scan for accuracy of prints. The combination of multiple print heads and scanning allows for the on-demand production of intricate electronic components. 2. Andy Kurk, TechShot, Inc. Techshot, Inc. has collaborated extensively with NASA on the in space manufacturing of both printed electronics and fused metal materials. They are currently working to develop and integrate a test system for printed electronics, and a flight demonstration on the International Space Station is anticipated in 2024. 3. Ed Hendricks, NextFlex. NextFlex has the goal of advancing the manufacture of flexible hybrid electronics in the U.S. They are working with ODME on the development of AstroSense, an additively manufactured, wireless, flexible, and wearable health sensor. 4. Dr. Pradeep Lall, Auburn University. Professor Lall is the MacFarlane Endowed Distinguished Professor in the Department of Mechanical Engineering with a Courtesy Joint Appointment in the Department of Electrical and Computer Engineering and a Courtesy Joint Appointment in the Department of Finance. He is collaborating with NASA’s ODME project to develop multilayer printable devices and to develop techniques to test the quality of a printed electronic device. 5. Dr. Wei Gao, California Institute of Technology. Professor Gao is an Assistant Professor of Medical Engineering. His group is developing fully printed, flexible, and wearable biosensors for crew health monitoring in collaboration with NASA’s ODME project. In addition, they are working on using sweat to power biofuel cells for wearable, self-powered electronic devices. 6. Beth Paquette, NASA Goddard. The ODME branch at NASA Goddard is spearheading a sounding rocket flight demo to prove the capability of a printed electronic device with multiple sensors. In addition, they focus on thin film and flexible energy storage evaluations. o Session Goal(s)/Outcome(s): Please list the learning objectives and/or tangible outcomes (technical paper or other publication). The goal of this session is to highlight the internal and collaborative efforts of NASA’s On Demand Manufacturing of Electronics project to develop a system for printing electronics that will be tested on the International Space Station in 2024. In addition, the session with facilitate discussion with the community on the state of the art of printable electronics, current challenges, and new avenues for collaboration.

Jennifer McInnis Jones↗
NASA NTRSDate not supplied

Characterization of Collection Efficiency of the Common Research Model Midspan Wing Section in the IRT

This paper presents a preliminary study for the characterization of collection efficiency from icing tests conducted in the Icing Research Tunnel at NASA Glenn Research Center. A test method previously developed for measuring the attachment line maximum collection efficiency of a swept NACA 0012 airfoil model at zero angle of attack was applied to the leading-edge region of a 65%-scale version of the Common Research Model midspan wing section. A correlation for the stagnation line maximum collection efficiency as a function of the modified inertia parameter was obtained with LEWICE3D simulations utilizing a discrete number of drop diameters. It was then compared with the collection efficiency measurement data obtained in the IRT. For the experimental collection efficiency, two ice shape digitization procedures were utilized to extract 2-D chord-wise ice shape profiles, i.e., the Maximum Combined Cross Section or MCCS, and the Minimum Combined Cross Section or Min CCS, at selected span-wise locations from the 3-D scanned ice shapes. The preliminary result showed that the rime ice thickness method can be used to characterize the collection efficiency distribution, for conditions free of ice erosion, in the main ice shape region. However, a high-order statistical processing of the ice scan is needed for estimating the mean ice thickness in areas where feathers are prevalent. From the limited comparison of the experimental and LEWICE3D collection efficiency data in the CRM65 MS model leading edge area, it was shown that the attachment line maximum collection efficiency is reasonably estimated by the best curve-fit correlation in the range of modified inertia parameter tested. A tighter alignment control of the iced and cold clean model scans is needed to improve the comparison. Further evaluation of this correlation is recommended to assess its applicability for Common Research Model type swept wing icing scaling analysis.

Ice Scailing↗
NASA NTRSDate not supplied

Characterization of Collection Efficiency of the Common Research Model Midspan Wing Section in the IRT

This paper presents a preliminary study for the characterization of collection efficiency from icing tests conducted in the Icing Research Tunnel at NASA Glenn Research Center. A test method previously developed for measuring the attachment line maximum collection efficiency of a swept NACA 0012 airfoil model at zero angle of attack was applied to the leading-edge region of a 65%-scale version of the Common Research Model midspan wing section. A correlation for the stagnation line maximum collection efficiency as a function of the modified inertia parameter was obtained with LEWICE3D simulations utilizing a discrete number of drop diameters. It was then compared with the collection efficiency measurement data obtained in the IRT. For the experimental collection efficiency, two ice shape digitization procedures were utilized to extract 2-D chord-wise ice shape profiles, i.e., the Maximum Combined Cross Section or MCCS, and the Minimum Combined Cross Section or MinCCS, at selected span-wise locations from the 3-D scanned ice shapes. The preliminary result showed that the rime ice thickness method can be used to characterize the collection efficiency distribution, for conditions free of ice erosion, in the main ice shape region. However, a high-order statistical processing of the ice scan is needed for estimating the mean ice thickness in areas where feathers are prevalent. From the limited comparison of the experimental and LEWICE3D collection efficiency data in the CRM65 MS model leading edge area, it was shown that the attachment line maximum collection efficiency is reasonably estimated by the best curve-fit correlation in the range of modified inertia parameter tested. A tighter alignment control of the iced and cold clean model scans as well as the model angle of attack are needed to improve the comparison. Further evaluation of this correlation is recommended to assess its applicability for Common Research Model type swept wing icing scaling analysis.

Icing Scaling↗
NASA NTRSDate not supplied

Comparison of Ice Shapes on Full-Chord and Truncated Swept Wing Models

A research program was conducted to evaluate the effectiveness of icing tunnel hybrid model design. A hybrid design is where the full-scale leading edge of a wing section is maintained only to a certain percentage of the local chord, while the aft section of the model is redesigned into a shortened or truncated planform. Ice shape geometries on a full-chord length and hybrid versions of the swept CRM65 wing model were obtained in NASA Icing Research Tunnel and compared. For most test conditions, the overall size and shape of the ice shapes compared well. On the main part of the ice shape, the hybrid model had larger chordwise extent, resulting in wider ice shape. For the scallop ice shapes, the ice shape heights at attachment line location were identical. For conditions that produced rime shape, hybrid model ice shapes were larger overall, even at the attachment line location. The only location where there was more ice on the full chord model was on the lower surface, downstream of where the hybrid model no longer had full-scale leading edge. For the test conditions where ice mass measurements were acquired for both models, the full-chord models had 11-22% less ice mass than on the hybrid wing. These differences were larger and opposite of those predicted from LEWICE 3D ice prediction calculations. Further investigation is needed in order determine the cause of the differences between the full-chord and hybrid models.

Icing↗
NASA NTRSDate not supplied

Comparison of Ice Shapes on Full-Chord and Truncated Swept Wing Models

A research program was conducted to evaluate the effectiveness of icing tunnel hybrid model design. A hybrid design is where the full-scale leading edge of a wing section is maintained only to a certain percentage of the local chord, while the aft section of the model is redesigned into a shortened or truncated planform. Ice shape geometries on a full-chord length and hybrid versions of the swept CRM65 wing model were obtained in NASA Icing Research Tunnel and compared. For most test conditions, the overall size and shape of the ice shapes compared well. On the main part of the ice shape, the hybrid model had larger chordwise extent, resulting in wider ice shape. For the scallop ice shapes, the ice shape heights at attachment line location were identical. For conditions that produced rime shape, hybrid model ice shapes were larger overall, even at the attachment line location. The only location where there was more ice on the full chord model was on the lower surface, downstream of where the hybrid model no longer had full-scale leading edge. For the test conditions where ice mass measurements were acquired for both models, the full-chord models had 11-22% less ice mass than on the hybrid wing. These differences were larger and opposite of those predicted from LEWICE 3D ice prediction calculations. Further investigation is needed in order determine the cause of the differences between the full-chord and hybrid models.

Icing↗
NASA NTRSDate not supplied

Internal Architecture of the Common Habitat

The core stage liquid oxygen tank of the Space Launch System can be manufactured as a habitat instead of as a propellant tank, with a common design such that it is equally suitable for use in 0g, 1/6g, 3/8g, 1g, or variable artificial gravity. This Common Habitat can be the central element of a human spaceflight architecture that encompasses the Moon, Mars, and other destinations within the inner solar system. The Common Habitat is specifically used within an alternative architecture study (that is not part of the current NASA baseline) as the core habitation element within a Lunar Basecamp, Mars Basecamp, and the Deep Space Exploration Vehicle. The Common Habitat internal architecture applies a design philosophy to separate crew functions according to deck. The lower deck is reserved for private functions. It includes eight private crew quarters and four waste and hygiene clusters – each with a private waste management compartment, private full body hygiene compartment, and foyer/clothes changing area. The mid deck is primarily allocated to mission-related working functions. It includes an exercise facility, fabrication / maintenance / repair facility, physical science laboratory (physics, geology, and astronomy), and life science laboratory (biology and human research). The mid deck also has four external hatches, clocked one every 90 degrees, centered on the vehicle vertical centerline. Each hatch has a 60-inch tall by 40-inch wide opening with the mid deck floor 16 inches below the bottom lip of the hatch opening. The upper deck is primarily allocated to group or social functions. It includes a large galley, wardroom with projector and display screen, plant growth chambers, bulk stowage, command and control station, medical facility, hygiene compartment, and vehicle subsystems. A Vertical Translation System, based in part on results from a GrabCAD public challenge, enables crew and equipment traverse between habitat decks in 0g, 1/6g, 3/8g, and 1g. A 40-inch by 60-inch vertical translation corridor ensures that anything that can fit through the external hatches can also be moved from deck to deck. The system includes three component systems: a deploying floor to safety barrier system that folds down to become a traversable floor when vertical translation is not in use and deploys to become a safety barrier during vertical translations; a folding ladder that stows in the ceiling when not in use; and an elevator platform that can attach to the ladder for cargo or incapacitated crew member transport. This system is complemented by a Horizontal Translation System, also based in part on the same GrabCAD challenge, provides for horizontal crew translation in microgravity but requires no vehicle reconfiguration for fractional or whole gravity operation. It relies primarily on gecko-inspired grippers, originally developed at Stanford and NASA JPL, attached to footwear to enable crew to emulate walking. Some handrails are also strategically placed throughout the Common Habitat to aid translation in both gravity and microgravity environments.

Common Habitat↗
NASA NTRS2021

Customized Science Carrier Modules and Accessories Developed for Microgravity Simulation Devices

Because the access to the true weightless environment of the ISS and other Low Earth Orbit (LEO) vehicles is limited and cost prohibitive, the need for ground-based microgravity simulation analogs to bridge the gravity continuum gap between 1g gravity and costly space flight studies with true weightlessness was realized. As such, the Microgravity Simulation Support Facility (MSSF) was established at NASA John F. Kennedy Space Center (KSC) to fulfill the need of the scientific community. Our facility provides the US science community with a focal point in the field of gravitational research by granting access to an array of two-dimensional(2D) and three-dimensional (3D)clinostats, and Random Positioning Machine (RPM) platforms developed by teams throughout the world. The availability of these capabilities will allow further understanding the role of altered gravity vectors from “functional weightlessness”, partial gravity conditions (1 x 10-3to 0.9g, and Moon and Mars ‘g vectors), to hypergravity (up to3g) on biological processes. We have designed and 3D printed a variety of specialized attachments(and associated “static control” hardware)to allow researchers to mount their samples onto these microgravity simulation devices to meet their unique science requirements. A summary of each attachment module will be presented below. Note: All software or code information should be requested to the author Ye Zhang, Kennedy Space Center ye.zhang-1@nasa.gov

Ye Zhang↗
NASA NTRS2020

Evaluation of a Method to Retrieve Temperature and Wind Velocity Profiles of the Venusian Nightside Mesosphere from Mid-Infrared CO2 Absorption Line Observed by Heterodyne Spectroscopy

We evaluated a method for retrieving vertical temperature and Doppler wind velocity profiles of the Venusian nightside mesosphere from the CO2 absorption line resolved by mid-infrared heterodyne spectroscopy. The achievable sensitive altitude and retrieval accuracy were derived with multiple model spectra generated from various temperature and wind velocity profiles with several noise levels. The temperature profiles were retrieved at altitudes of 70–100 km with a vertical resolution of 5 km and a retrieval accuracy of ±15 K. The wind velocity was also retrieved at an altitude of approximately 85 km with a vertical resolution of 10 km and a retrieval accuracy of ± 25–50 m/s. In addition, we studied an event and applied our method to spectra obtained by the HIPWAC instrument attached to the NASA/IRTF 3-m telescope on May 19–22, 2012. Retrieved wind velocities in a latitude of 33° S at 3:00 LT were interpreted as subsolar-to-antisolar (SS-AS) flows at altitudes of 84 ±6 km and 94 ±7 km, and they were stronger than expected. This result suggested that the transition between the retrograde super rotational zonal (RSZ) wind and SS-AS flow may occur at altitudes below 90 km which previously was predicted to be the transition region. This work provides a basis for our analysis of further observations obtained by a mid-infrared heterodyne spectrometer MILAHI attached to the Tohoku University 60-cm telescope at Haleakalā, Hawaii.

Venus↗
NASA NTRSDate not supplied

Advancements in Force and Angle Measurement by the NFMTC

The National Force Measurement Technology Capability (NFMTC) is a nationwide partnership established in 2008 and sponsored by NASA’s Aeronautics Evaluation and Test Capabilities (AETC) project to maintain and further develop force and angle measurement capabilities primarily for NASA’s ground test facilities. One of the NFMTC’s primary objectives is to develop new force and angle measurement capabilities to meet the needs of researchers testing in NASA’s ground test facilities. This work will highlight several new capabilities that are either at or near operational readiness. A new six-component flow-through balance was designed and fabricated to support an upcoming retropropulsion test campaign at the NASA Langley Unitary Plan Wind Tunnel. The balance employs membranes in place of bellows, which have historically been used, and passes the flow through load bearing parts of the balance. Flow through the balance is optimized via the addition of flow guides, which are manufactured as separate parts, and attached to the balance. Calibration of this new flow-through balance demonstrates that it can suitably characterize the load and pressure ranges it was designed for, which provides aero researchers a new tool to directly measure retropropulsion performance of powered descent vehicles. Balances used in NASA’s ground test facilities are typically either single-piece balances or floating-frame balances. Historically, these two types of balances have generally used different front-end (model) attachments. Single-piece balances generally have a cylindrical front end that is forward of any measuring sections and at a reduced diameter relative to the balance outer diameter. Floating-frame balances generally have front end fits that extend over one or more measuring sections and that engage at the balance outer diameter. Recently, the NFMTC fabricated a single-piece balance with a front end fit that is compatible with the hardware used to calibrate floating-frame balances. Calibration results evaluating this front end fit will be presented. From a recent survey of angle measurement needs, the development of smaller angle measurement packages was identified as one area of improvement. Micro-electromechanical systems (MEMS) are continually being refined to provide high performance accelerometers that are a fraction of the volume of the quartz flexure based accelerometers that are standard in wind tunnels. A survey of commercial off-the-shelf MEMS accelerometers was conducted, and it identified the Safran Colibrys MS lines to be of adequate performance. Single-axis test boards and tri-axis rigid-flex production boards were designed and fabricated with a volume of approximately .18 cubic inches. The boards were designed to provide all the necessary conditioning for the MEMS accelerometers at levels to meet or exceed all requirements for the MS line sensors. Preliminary testing of these assembled sensor packages has demonstrated acceptable performance for wind-tunnel angle measurement. Several new rotating balances are at various stages of completion for NASA Glenn Research Center’s fan drive rigs. These balances provide direct measurement of thrust and torque of a driven fan or fan section to provide an estimate of fan efficiency and net thrust. Three two-component balances have been recently completed, and one six-component balance is in active development. A custom rotating telemetry system has been developed to support testing with these balances, and the telemetry system is integrated into the forward end of each one. The telemetry system is designed to remove mechanical sliprings by using an optical ethernet-based slipring for data transmission.

Force measurement↗
NASA NTRS2022

X-59 Sonic Boom Test Results from the NASA Glenn 8- by 6-Foot Supersonic Wind Tunnel

A wind tunnel test was conducted to investigate near-field sonic boom pressure signatures from a model of the X-59 Low-Boom Flight Demonstrator aircraft. A 1.62%-scale model of the aircraft in the C612A configuration was fabricated for the wind tunnel test, which took place in the NASA Glenn 8- by 6-Foot Supersonic Wind Tunnel in September and October 2021. The model had provisions for two different mounting options: a swept blade strut that attached at the top of model ahead of the inlet, and rear-entry sting that was made as one piece with a dummy nacelle, and which had a 2”-long cylindrical segment aft of the nozzle exit before tapering up in size. The blade strut allowed for a clean aft end of the model for evaluation of the shocks from that region, while the sting avoided the significant distortions of the flow and shocks from the blade strut along the top of the model. Both the sting and the strut had adapters that attached to a force balance. The model had alternate parts for ±0.5° deflections of the flaps, ailerons, and stabilator, and ±1° deflections of the T-tail horizontal surface. Off-body static pressure measurements of the flow field below the model were made by use of a pressure rail which had 420 orifices along its tip. The model was positioned at various heights from the rail by vertical movement of the wind tunnel strut, and at various longitudinal stations relative to the rail by means of a linear actuator mounted between the tunnel strut and the balance. The longitudinal positioning allowed multiple pressure signatures to be obtained along different portions of the rail. These signatures were aligned by accounting for the model longitudinal movement and then averaged to take out the effects of tunnel flow distortions and the interference of the rail flow field and shocks on the model pressure signatures. The test was run at approximate Mach numbers of 1.36, 1.4, and 1.47, and the model was set at various angles of attack and roll relative to the rail. Plots of the model signatures for all the variations of Mach number, model angles, control deflections, and height relative to the rail are provided throughout the report. Repeatability was generally very good and gave confidence in the quality of the measurements. The signatures measured at various heights from the rail provided insight into the aging of the model shocks as they propagated from 1.2 to 3 body lengths from the model. Off-track signatures up to 45° from centerline obtained by rolling the model gave indications of the shock flow fields across the width of the sonic boom carpet. The deflections of the various control surfaces allowed assessment of the boom sensitivity to the control surface movements.

Sonic boom↗
NASA NTRS2023

Modeling and Simulation of the Angel Upper Limb Offload Device: Branching Into New Methods

BACKGROUND: The Active Response Gravity Offload System (ARGOS) provides an analog environment for extravehicular activity (EVA) testing and training. Discomfort has been observed during longer suited test sessions. While the subject’s core is offloaded during surface EVA evaluations, his/her arms experience full Earth gravity and can become overly fatigued, especially during suited tests which involve reaching and prolonged arm extensions. A device (ARGOS Negation of Gravitational Effects on the Limbs: ANGEL) to offload the weight of the arms and suit sleeves is being developed by JSC’s Flight Systems Branch of the Software, Robotics, and Simulation Division. Previously we have shared preliminary modeling of that device and kinematics based on motion capture data. Here we present an alternative approach to determine device kinematics by calculating ANGEL component angles with an OpenSim plugin. We compare calculated angles to inverse kinematics (IK) derived ones with the goal of validating the model. This new method can be further informative for device design and analytically testing different configurations to achieve desired reduced gravity conditions (e.g., lunar gravity (Lg) or Martian gravity (Mg)). We have compared calculated angles with IK-derived angles in tests with a shirt-sleeve subject positioned in a test stand with a Mark-III Hard Upper Torso (HUT) and Portable Life Support System (PLSS) mockup and arm weights to emulate the weight of the suit sleeve as well as a suited subject in ARGOS with a Mark-III suit. A variety of upper body tasks were completed in the former and full-body tasks in the latter. METHODS AND RESULTS: To model the offload device, we augment the OpenSim human model topology with the offload mechanism components and joints, using CAD models to represent the mechanism graphically. The joint angles of the device are calculated in the OpenSim plugin by modeling how the components configure themselves under the offloading spring tension given a particular IK-derived arm position. There are four ANGEL components with a total of 5 degrees of freedom (DOFs), each component has a single DOF except for the cuff which is modeled as 2 DOFs. The sickle/yaw bracket and cuff rotation angles are determined statically based on the assumptions that the sickle will track the attachment point of the cuff and that the cuff will rotate such that the attachment point is at its highest point. The cuff tilt, linker and V-bracket angles are then determined by optimizing their positions to approach a mechanical equilibrium. The calculated linker angle is compared to three different methods of determining the linker line-of-force kinematically (from V-bracket to center-cuff, cuff highest point or marker-derived position). Given the joint angles of the device, the spring force and resulting force on the arm is computed by the plugin and applied as an external load in inverse dynamics (ID) to enable study of overall shoulder joint torques as well as offload achieved. We verify the calculated joint angles by using the inverse kinematic data. The average difference in angles is the smallest for the V-bracket and linker, around 1 to 5 degrees for most trials. The resulting offload and shoulder torque are comparable between calculated and IK-derived angles. In summary, we have developed a method to calculate the joint angles of an exoskeleton-like upper limb offloading device currently in development. We have also developed a custom plugin which will be a valuable tool to optimize device configurations for a desired gravitational environment, probe the offload achieved for motions recorded outside of our test suite, and inform future design improvements.

L B Nilsson↗
NASA NTRSDate not supplied

Measurements and Computations of the Turbulent Corner Flow on the NASA Juncture-Flow Model with a Symmetric Wing

The NASA Juncture Flow experiment is designed to acquire high-quality flowfield data deep in the corner of a wing-fuselage junction specifically for the purpose of computational fluid dynamics (CFD) validation and turbulence model improvement. This paper presents and discusses the results of a recent experiment with the juncture-flow model in the NASA Langley 14- by 22-Foot Subsonic Tunnel. The main objective of the test was to expand the existing juncture-flow dataset with a symmetric wing case that displays fully attached, incipient separation, and separated flow in the corner of the wing-fuselage junction, depending on the model angle of incidence. Laser Doppler velocimetry (LDV) measurements were made at three model angles of incidence (0 deg: fully attached, 1 deg: incipient separation, and 5 deg: separated flow) and for each one, mean-flow and Reynolds-stress data were obtained on the fuselage and at several streamwise locations along the corner of the wing-fuselage junction. Supporting measurements were made during the test campaign and included model and tunnel wall static pressures, tunnel wall and ceiling boundary-layer rake data, oil-flow visualizations, and laser-based measurements of the as-built model geometry and model position in the test section. Comparisons between the experimental data on the test article and Reynolds-averaged Navier-Stokes CFD results are presented and discussed.

Juncture Flow↗
NASA NTRSDate not supplied

Overview of the High Reynolds Number Ascent Wind Tunnel Test of the Space Launch System at the National Transonic Facility

Transonic, high Reynolds number wind tunnel testing for the Space Launch System (SLS) ascent flight environment was conducted in the National Transonic Facility (NTF) at the NASA Langley Research Center from December 2019 to April 2021. The test was sponsored by the SLS Program and the NASA Engineering & Safety Center with the ob- jective of assessing and characterizing Reynolds number effects on the ascent aerodynamics of the SLS launch vehicle. The cryogenic test article was a 1.75%-scale representation of the SLS Block 1 Cargo configuration that was fabricated mostly out of stainless steel, but with several additive-manufactured components including the Solid Rocket Booster (SRB) attach brackets and the SRB nozzles. This was the first use of additive manufacturing on structural components of a cryogenic model in the NTF, therefore post-fabrication material testing and inspections were performed to satisfy safety requirements. Force & moment and surface pressure data were acquired for Mach numbers between 0.50 and 0.95 over a range of Reynolds numbers based on core stage diameter between 2x10^6 and a maximum of 40x10^6 corresponding to 45% of flight Reynolds number. Additionally, flow visualization data using Pressure Sensitive Paint were acquired with a focus on the SRB forward attach area, which is susceptible to Reynolds number sensitivity at transonic speeds. This pa- per provides an overview of the test campaign including details on the unique test article and the experimental setup and test execution. General test findings and observations are also presented, but the majority of the test results and data analyses are provided in a companion paper.

Space Launch System↗
NASA NTRSDate not supplied

A Single-Piece Wind Tunnel Balance with a Universal Metric End

The metric attachment strategies for single and multi-piece wind tunnel balances have historically been distinct. This limits the interchangeability of single and multi-piece balances in wind tunnel models. In this work, a single-piece balance with a metric attachment compatible with a multi-piece balance (universal metric end) is designed, fabricated, and calibrated. The calibration results including the balance accuracies and deflections are reported for the new balance and compared to a single-piece balance with a conventional metric end designed to the same loads.

Wind tunnel balance↗
NASA NTRS2023

Measurements and Computations of the Turbulent Corner Flow on the NASA Juncture-Flow Model with a Symmetric Wing

The NASA Juncture Flow experiment is designed to acquire high-quality flowfield data deep in the corner of a wing-fuselage junction specifically for the purpose of computational fluid dynamics (CFD) validation and turbulence model improvement. This paper will present and discuss the results of a recent experiment with the juncture-flow model in the NASA Langley 14- by 22-Foot Subsonic Tunnel. The main objective of that test was to expand the existing juncture-flow dataset with a symmetric wing case that displays fully attached, incipient separation, and separated flow in the corner of the wing-fuselage junction, depending on the model pitch angle. Laser Doppler velocimetry (LDV) measurements were made at three model pitch angles (0 deg: fully attached, 1 deg: incipient separation, and 5 deg: separated flow) and for each one, mean-flow and Reynolds-stress data was obtained on the fuselage and at several streamwise locations along the corner of the wing-fuselage junction. Supporting measurements were made during the test campaign and included model and tunnel wall static pressures, tunnel wall and ceiling boundary-layer rake data, oil-flow visualizations, and laser-based measurements of the as-built model geometry and model position in the test section. Comparisons between the experimental data and Reynolds averaged Navier-Stokes CFD results will also be presented and discussed.

Juncture Flow↗
NASA NTRSDate not supplied

Manufacturing Trials of Integrally Stiffened Panels for Flight Applications

Reduced weight is an ever-increasing demand within the aerospace industry, and non-traditional means of achieving this demand are increasingly being considered. There is also a desire to reduce the manual labor involved in attaching thousands of parts together with rivets and other fasteners. Using advanced stiffener concepts can avoid the weight of fasteners and streamline fabrication by reducing the part count, while still providing the mandatory strength requirements for flight certification. Described herein is a set of manufacturing trials that were completed at NASA Langley Research Center to investigate the feasibility of various integrated stiffener concepts. Fully composite stiffeners that can be integrated or attached by other means, either through bonding or interleaving them within the skin, can remove the fasteners and still maintain a rapid manufacturing rate. This study contains these advanced stiffener concepts, and the lessons learned and design iterations that resulted from the series of manufacturing trials. Each set of trials was completed with an end goal of using tow-steered integral stiffeners for flight structure in composite aircraft wings.

Composite↗
NASA NTRSDate not supplied

Validation of Shadowgraph Spectral Analysis using an SLS Block 2 Wind-Tunnel Model

A flow quantification method has previously been developed that uses high-speed shadowgraph images to extract frequency content of a transonic flow field around a wind-tunnel model. In this method, a classical spectral analysis is performed on a set of shadowgraph image pixels to identify their intensity fluctuation frequencies. The spatial change of the image intensity is related to the second derivative of the density gradient. Examining the change of the density gradient as a function of time can be used to understand the flow field pressure fluctuations. Pressure measurements collected during a Booster Obsolescence Life Extension Forward Attachment Structure Trade Study Test are used to calibrate the shadowgraph-based measurements. The test was performed at the NASA Ames Research Center Unitary Plan Wind Tunnel 11- by 11-foot test section and investigated aerodynamic environment downstream of various booster forward attachment hardware geometries of the Space Launch System Block 2 Cargo configuration. Time-correlated shadowgraph video and model surface pressure measurements were acquired during the test and served as an ideal opportunity to calibrate and validate the shadowgraph image intensity method.

Shadowgraph↗