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Low-speed wind tunnel testing for the liftoff and transition environment of the Space Launch System (SLS) was recently completed in the NASA Langley Research Center 14- by 22-Foot Subsonic Tunnel using 1.75%-scale models of three SLS vehicle configurations. During the liftoff testing, the primary objective was to evaluate the aerodynamic forces and moments on the SLS launch vehicles, as the vehicle, launch tower, and mobile launch platform were subjected to ground winds from all directions at varying heights for the vehicle off the launch pad. Additionally, aerodynamic forces and moments were acquired for all three SLS vehicles during the transition phase from liftoff to ascent that covered a wide range of angles of attack and angles of side slip. Details of the experimental setup including improved testing methods and a stiffer sting-balance system based on lessons learned from previous test entries are presented. Also, a new force measurement technique was applied during the test where two subminiature six-component load cells were installed in each Solid Rocket Booster (SRB) to acquire forces and moments for each SRB separately from the full vehicle forces and moments measured by the main strain gauge balance. Finally, sample results from the experiment are presented including improved overall data coverage, evaluation of the new SRB data, and smoke flow visualization photos.

NASA’s National Transonic Facility is one of the few cryogenic wind-tunnel facilities in the world, where tunnel conditions may reach -250 F. Model angle of attack (AoA) at NTF is typically measured by an on-board accelerometer package that is exposed to the cryogenic tunnel conditions. These NTF AoA packages house two Q-Flex accelerometers in a compact heated environment in order to maintain constant temperature of the sensors for stability. Recently, drift in sensor output was observed in one of the NTF AoA packages. The drift is correlated with the AoA package temperature and cryogenic soak time. This paper studies the temperature and time dependent behavior of the NTF AoA packages, and reviews their design and calibration. Recommended improvements to the AoA packages are made to improve the stability of the model angle of attack measurements at cryogenic conditions.

Cryogenic wind-tunnel facilities face unique challenges in the calibration and operation of various measurement systems and instrumentation. Instruments that are subjected to the cryogenic conditions of the test plenum require careful design and calibration procedures to maintain instrument performance. NASA’s National Transonic Facility (NTF) and the European Transonic Windtunnel (ETW) are two cryogenic wind-tunnel facilities, each with the ability to calibrate force measurement systems (FMS) at cryogenic conditions. These facilities have different methodologies and processes for calibrating these systems. This paper discusses differences in the methodologies and processes and compares the results of two separate cryogenic calibrations of the NTF-118A force balance that were completed at both wind-tunnel facilities.

Discrepancies between the model and balance coordinate systems lead to biases in the aerodynamic measurements during wind-tunnel testing. The reference coordinate system relative to the calibration coordinate system at which the forces and moments are resolved is crucial to the overall accuracy of force measurements. This paper discusses sources of discrepancies and estimates of coordinate system rotation and translation due to machining and assembly differences. A methodology for numerically estimating the coordinate system biases will be discussed and developed. Two case studies are presented using this methodology to estimate the model alignment. Examples span from angle measurement system shifts on the calibration system to discrepancies in actual wind-tunnel data. The results from these case-studies will help aerodynamic researchers and force balance engineers to better the understand and identify potential differences in calibration systems due to coordinate system rotation and translation.

Wind tunnel research at NASA Langley Research Center s 31-inch Mach 10 hypersonic facility utilized a 5-component force balance, which provided a pressurized flow-thru capability to the test article. The goal of the research was to determine the interaction effects between the free-stream flow and the exit flow from the reaction control system on the Mars Science Laboratory aeroshell during planetary entry. In the wind tunnel, the balance was exposed to aerodynamic forces and moments, steady-state and transient thermal gradients, and various internal balance cavity pressures. Historically, these effects on force measurement accuracy have not been fully characterized due to limitations in the calibration apparatus. A statistically designed experiment was developed to adequately characterize the behavior of the balance over the expected wind tunnel operating ranges (forces/moments, temperatures, and pressures). The experimental design was based on a Taylor-series expansion in the seven factors for the mathematical models. Model inversion was required to calculate the aerodynamic forces and moments as a function of the strain-gage readings. Details regarding transducer on-board compensation techniques, experimental design development, mathematical modeling, and wind tunnel data reduction are included in this paper.

Design of Experiments (DOE) techniques were applied to the Launch Abort System (LAS) of the NASA Crew Exploration Vehicle (CEV) parametric geometry Computational Fluid Dynamics (CFD) study to efficiently identify and rank the primary contributors to the integrated drag over the vehicles ascent trajectory. Typical approaches to these types of activities involve developing all possible combinations of geometries changing one variable at a time, analyzing them with CFD, and predicting the main effects on an aerodynamic parameter, which in this application is integrated drag. The original plan for the LAS study team was to generate and analyze more than1000 geometry configurations to study 7 geometric parameters. By utilizing DOE techniques the number of geometries was strategically reduced to 84. In addition, critical information on interaction effects among the geometric factors were identified that would not have been possible with the traditional technique. Therefore, the study was performed in less time and provided more information on the geometric main effects and interactions impacting drag generated by the LAS. This paper discusses the methods utilized to develop the experimental design, execution, and data analysis.

†‡ § A Response Surface Methodology (RSM) approach to wind tunnel testing of aircraft with complex configurations is being investigated at the Langley Full-Scale Tunnel (LFST) as part of a series of tests using Design of Experiments (DOE). An exploratory study was conducted using RSM and a 5% scale blended wing body model in an effort to efficiently characterize aerodynamic behavior as a function of attitude and multiple control surface inputs. This paper provides a direct comparison of the DOE/RSM and one factor at a time (OFAT) methods for a low-speed wind tunnel test of a Blended-Wing-Body (BWB) aircraft configuration with eleven actuated surfaces. A modified fractional factorial design, augmented with center points and axial points, produced regression models for the characteristic aerodynamic forces and moments over a representative design space as a function of model attitude and control surface inputs. Model adequacy and uncertainty levels were described using robust statistical methods inherent to RSM practice. Experimental goals included the capture of fundamental stability and control data for simulation models and comparisons to baseline data from recent OFAT tests. Optimization is demonstrated for actuator allocation for a desired response. A discussion of highlights and problems associated with the test is included.

In the production of a high-quality measurement system, the criticality of the calibration phase is evidenced by a significant investment of resources. Applying statistical methods in tandem with instrumentation expertise has resulted in a dramatic reduction in calibration time and expense, while simultaneously improving the calibration quality. Specifically, in this paper, the foundational principles of response surface methodology and statistical quality control are presented with application to calibration. In addition, we report on the benefits that have been achieved by the integration of the experimental design with the mechanical calibration system. To demonstrate this systems engineering approach, we consider the calibration of two quintessential instruments used in aeronautical wind tunnel experiments, namely the force-balance and triaxial angle measurement system. For both instruments, we discuss the development of an experimental design that accommodates physics-based constraints and highlight an innovative calibration apparatus that provides an increase in calibration efficiency. As a direct result of increased efficiency, the frequency of calibration can be increased, enabling the monitoring of instrument stability over time. Throughout the calibration process, we emphasize the efficient allocation of experimental resources to achieve the calibration requirements.

This paper presents an uncertainty analysis of the Single-Vector Force Balance Calibration System (SVS). This study is focused on the uncertainty involved in setting the independent variables during the calibration experiment. By knowing the uncertainty in the calibration system, the fundamental limits of the calibration accuracy of a particular balance can be determined. A brief description of the SVS mechanical system is provided. A mathematical model is developed to describe the mechanical system elements. A sensitivity analysis of these parameters is carried out through numerical simulations to assess the sensitivity of the total uncertainty to the elemental error sources. These sensitivity coefficients provide valuable information regarding the relative significance of the elemental sources of error. An example calculation of the total uncertainty for a specific balance is provided. Results from this uncertainty analysis are specific to the Single-Vector System, but the approach is broad in nature and therefore applicable to other measurement and calibration systems.

A need for low-speed, high Reynolds number test capabilities has been identified for the design and development of advanced subsonic transport high-lift systems. In support of this need, multiple investigations have been conducted in the National Transonic Facility (NTF) at the NASA Langley Research Center to develop a semi-span testing capability that will provide the low-speed, flight Reynolds number data currently unattainable using conventional sting-mounted, full-span models. Although a semi-span testing capability will effectively double the Reynolds number capability over full-span models, it does come at the expense of contending with the issue of the interaction of the flow over the model with the windtunnel wall boundary layer. To address this issue the size and shape of the semi-span model mounting geometry have been investigated, and the results are presented herein. The cryogenic operating environment of the NTF produced another semi-span test technique issue in that varying thermal gradients have developed on the large semi-span balance. The suspected cause of these thermal gradients and methods to eliminate them are presented. Data are also presented that demonstrate the successful elimination of these varying thermal gradients during cryogenic operations.