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Small Propeller and Rotor Testing Capabilities of the NASA Langley Low Speed Aeroacoustic Wind Tunnel

The Low Speed Aeroacoustic Wind Tunnel (LSAWT) at NASA Langley Research Center has recently undergone a configuration change. This change incorporates an inlet nozzle extension meant to serve the dual purposes of achieving lower free-stream velocities as well as a larger core flow region. The LSAWT, part of the NASA Langley Jet Noise Laboratory, had historically been utilized to simulate realistic forward flight conditions of commercial and military aircraft engines in an anechoic environment. The facility was modified starting in 2016 in order to expand its capabilities for the aerodynamic and acoustic testing of small propeller and unmanned aircraft system (UAS) rotor configurations. This paper describes the modifications made to the facility, its current aerodynamic and acoustic capabilities, the propeller and UAS rotor-vehicle configurations to be tested, and some preliminary predictions and experimental data for isolated propeller and UAS rotor con figurations, respectively. Isolated propeller simulations have been performed spanning a range of advance ratios to identify the theoretical propeller operational limits of the LSAWT. Performance and acoustic measurements of an isolated UAS rotor in hover conditions are found to compare favorably with previously measured data in an anechoic chamber and blade element-based acoustic predictions.

Zawodny, Nikolas S.↗

Prospects for Nonlinear Laser Diagnostics in the Jet Noise Laboratory

Two experiments were conducted to test whether optical methods, which rely on laser beam coherence, would be viable for off-body flow measurement in high-density, compressible-flow wind tunnels. These tests measured the effects of large, unsteady density gradients on laser diagnostics like laser-induced thermal acoustics (LITA). The first test was performed in the Low Speed Aeroacoustics Wind Tunnel (LSAWT) of NASA Langley Research Center's Jet Noise Laboratory (JNL). This flow facility consists of a dual-stream jet engine simulator (with electric heat and propane burners) exhausting into a simulated flight stream, reaching Mach numbers up to 0.32. A laser beam transited the LSAWT flow field and was imaged with a high-speed gated camera to measure beam steering and transverse mode distortion. A second, independent test was performed on a smaller laboratory jet (Mach number < 1.2 and mass flow rate < 0.1 kg/sec). In this test, time-averaged LITA velocimetry and thermometry were performed at the jet exit plane, where the effect of unsteady density gradients is observed on the LITA signal. Both experiments show that LITA (and other diagnostics relying on beam overlap or coherence) faces significant hurdles in the high-density, compressible, and turbulent flow environments similar to those of the JNL.

Herring, Gregory C.↗

Aerodynamic Performance and Acoustic Measurements of a High-Lift Propeller in an Isolated Configuration

A series of aerodynamic performance and acoustic measurements has been made on a high-lift propeller intended for utilization on a distributed electric propulsion (DEP) aircraft. Tests were performed in the NASA Langley Low Speed Aeroacoustic Wind Tunnel (LSAWT), which has recently undergone a capability enhancement for the testing of small propellers/rotors and small unmanned aircraft system (UAS) platforms. The objectives of this testing campaign are two-fold: first to demonstrate the facility capabilities for performing small propeller aeroacoustic testing, and second to compare experimental measurements with computational fluid dynamic (CFD) predictions and CFD-based acoustic predictions of the tested propeller configurations for tool development and validation purposes.

Zawodny, Nikolas S.↗

Acoustic Wind Tunnel Measurements of a Quadcopter in Hover and Forward Flight Conditions

An experimental testing campaign was conducted in the NASA Langley Low Speed Aeroacoustic Wind Tunnel (LSAWT) in order to better understand the acoustic characteristics of a representative quadcopter system in both hover and forward flight conditions. Aerodynamic performance measurements were acquired using a multi-axis load cell to trim the vehicle to desired thrust/lift conditions. Hover acoustic measurements provide evidence of prominent rotor-airframe interaction noise that manifests in the form of high-amplitude harmonics of the fundamental rotor blade passage frequency. Forward flight acoustic measurements of simultaneous rotor operations indicate the presence of strong forward-aft rotor wake interactions that yield increased broadband noise levels relative to cases of individual rotor operation. These results indicate the potential need for modeling complex noise generation mechanisms associated with multirotor and rotor-airframe interactions for vehicles of this class.

Zawodny, Nikolas S.↗

Aerodynamic and Acoustic Interactions Associated with Inboard Propeller-Wing Configurations

A series of aerodynamic performance and acoustic measurements have been made on a range of inboard propeller-wing interaction configurations in the NASA Langley Low Speed Aeroacoustic Wind Tunnel (LSAWT). The results presented in this paper are part of a more expansive testing campaign encompassing both single propeller-wing and multipropeller-wing interactions, the former of which is discussed in the present work. The primary testing parameters of interest to this study are the axial and vertical positioning of the wing relative to the propeller slipstream under a constant propeller advance ratio. A multi-faceted computational effort was also employed in an effort to identify reflection and scattering effects imposed by both the wing geometry as well as the primary components of the facility test setup. This effort consisted of aerodynamic predictions using high-fidelity computational fluid dynamics (CFD), acoustic predictions using an impermeable Ffowcs Williams and Hawkings (FW-H) solver, and acoustic scattering predictions. Acoustic measurements reveal variations in the acoustic directivity behavior of the propeller blade passage frequency for even modest variations in wing position. CFD-based acoustic predictions reveal discrepancies relative to the experimental data, which is believed to be due to complex acoustic scattering behavior within the test section. Initial attempts at modeling the scattered acoustic field showed functional dependency of the acoustic amplitude variations on the wing position relative to the propeller disk, however discrepancies with experimental data remain.

Nikolas S. Zawodny↗

Aeroacoustic Testing of UAS-Scale Rotors for a Quadcopter in Hover and Forward Flight

A series of experiments was conducted in an anechoic chamber and wind tunnel to investigatethe noise and performance of an optimum hovering rotor design. The optimum hovering rotorexperimental data set presented in this paper provides the community with a rotor that istheoretically easier to model. Isolated rotors were tested in an anechoic hover chamber as wellas on a representative quadcopter vehicle. In the anechoic chamber, performance and acousticmeasurements were taken at various rotor speeds to compare to those of a commercial-off-the-shelf (COTS) rotor. In the wind tunnel, free-stream velocity, vehicle pitch, and rotor rotationrates were varied to achieve various hover and forward flight operating conditions. Previousinvestigation of a small quadcopter in the Low Speed Aeroacoustic Wind Tunnel (LSAWT) hadidentified possible broadband and interactional noise sources due to rotor airframe interactionand rotor-rotor interaction. These publications identified separation, turbulent boundary layertrailing edge, and bluntness vortex shedding as the main sources of self-generated airfoil noise.By replacing the COTS rotor with an optimum hovering rotor design, self-generated broadbandnoise was reduced for both hover and forward flight conditions for isolated rotor runs. However,the optimum rotors only reduced noise levels for full-vehicle hover conditions, and had little tono reduction in full-vehicle forward flight conditions.

Nicole A Pettingill↗

X-57 “Maxwell” High-Lift Propeller Testing and Model Development

NASA’s X-57 “Maxwell” distributed electric propulsion flight demonstrator has a high-lift system that includes 12 fixed-pitch high-lift propellers located upstream of the wing leading edge for lift augmentation at low speeds. These high-lift propellers are not required at higher speeds and are folded conformally along the nacelles to reduce drag when not in operation. Aircraft performance models and flight simulations incorporate propeller performance to predict thrust, moments, and power consumption and propeller model accuracy is important in identifying safe operating regimes for this aircraft. Current high-lift propeller performance models have been verified and calibrated against numerous computational fluid dynamics analyses under a variety of flight conditions. We performed a series of full-scale wind tunnel tests at the NASA Langley Research Center Low Speed Aeroacoustic Wind Tunnel to further validate these models, to identify any adverse operating conditions for these propellers, and to assess the accuracy of the facility’s new Propeller Test Stand. The results indicate that the models accurately predicted performance and that the right-handed propeller showed lower torque and thrust for a given propeller speed compared to the left-handed version. Acoustic data support these measurements, showing higher tonal noise for the left versus right propeller. We suspect this is due to slight differences in the material properties between the early production (right) and more recent (left) blade sets leading to greater detwisting in the right-handed blades under load. Both propellers demonstrated very stable operation throughout the test including during deployment, stowing, and windmilling. Furthermore, high-speed imagery of the spinning propeller indicated no blade oscillations or instabilities for any test case. We also leveraged these images to analyze the effects of propeller loading on blade detwisting and tip position. Unfortunately, the thrust measurements varied significantly during the test due to cross-loading of the Propeller Test Stand load cell, though trends in the thrust data were still observable. The torque measurement, however, remained very precise for all test points and was used for performance comparisons. As a result of this test, we validated and improved the X-57 high-lift propeller performance models, obtained detailed propeller acoustic data and high-speed imagery, observed the propeller operating safely during a variety of dynamic events, and identified two potentially adverse, low-propeller-speed conditions which will be avoided during normal aircraft operation.

X-57↗