Gary A. Fleming

Modeling, Fabrication, and Testing of a SMA Hybrid Composite Jet Engine Chevron Concept

This study presents a fabrication method, bench top test results, and numerical model validation for a novel adaptive jet engine chevron concept based upon embedding shape memory alloy (SMA) actuators in a composite laminate, termed a SMA hybrid composite (SMAHC). The approach for fabricating the adaptive SMAHC chevrons involves embedding prestrained Nitinol actuators on one side of the mid-plane of the composite laminate such that thermal excitation generates a thermal moment and deflects the structure. A rigorous and versatile test system for control and measurement of the chevron deflection performance is described. A recently commercialized constitutive model for SMA and SMAHC materials is used in the finite element code ABAQUS to perform nonlinear static analysis of the chevron specimens. Excellent agreement is achieved between the predicted and measured chevron deflection performance, thereby validating the numerical model and enabling detailed design of chevron prototype(s) and similar structures.

Measurement of Rotorcraft Blade Deformation Using Projection Moiré Interferometry

Projection Moire Interferometry (PMI) has been used to obtain near instantaneous, quantitative blade deformation measurements of a generic rotorcraft model at several test conditions. These laser-based measurements provide quantitative, whole field, dynamic blade deformation profiles conditionally sampled as a function of rotor azimuth. The instantaneous nature of the measurements permits computation of the mean and unsteady blade deformation, blade bending, and twist. The PMI method is presented, and the image processing steps required to obtain quantitative deformation profiles from PMI interferograms are described. Experimental results are provided which show blade bending, twist, and unsteady motion. This initial proof-of-concept test has demonstrated the capability of PMI to acquire accurate, full field rotorcraft blade deformation data.

Contributions of the NASA Langley Research Center to the DARPA/AFRL/NASA/ Northrop Grumman Smart Wing Program

An overview of the contributions of the NASA Langley Research Center (LaRC) to the DARPA/AFRL/NASA/ Northrop Grumman Corporation (NGC) Smart Wing program is presented. The overall objective of the Smart Wing program was to develop smart** technologies and demonstrate near-flight-scale actuation systems to improve the aerodynamic performance of military aircraft. NASA LaRC s roles were to provide technical guidance, wind-tunnel testing time and support, and Computational Fluid Dynamics (CFD) analyses. The program was divided into two phases, with each phase having two wind-tunnel entries in the Langley Transonic Dynamics Tunnel (TDT). This paper focuses on the fourth and final wind-tunnel test: Phase 2, Test 2. During this test, a model based on the NGC Unmanned Combat Air Vehicle (UCAV) concept was tested at Mach numbers up to 0.8 and dynamic pressures up to 150 psf to determine the aerodynamic performance benefits that could be achieved using hingeless, smoothly-contoured control surfaces actuated with smart materials technologies. The UCAV-based model was a 30% geometric scale, full-span, sting-mounted model with the smart control surfaces on the starboard wing and conventional, hinged control surfaces on the port wing. Two LaRC-developed instrumentation systems were used during the test to externally measure the shapes of the smart control surface and quantify the effects of aerodynamic loading on the deflections: Videogrammetric Model Deformation (VMD) and Projection Moire Interferometry (PMI). VMD is an optical technique that uses single-camera photogrammetric tracking of discrete targets to determine deflections at specific points. PMI provides spatially continuous measurements of model deformation by computationally analyzing images of a grid projected onto the model surface. Both the VMD and PMI measurements served well to validate the use of on-board (internal) rotary potentiometers to measure the smart control surface deflection angles. Prior to the final entry, NASA LaRC also performed three-dimensional unstructured Navier Stokes CFD analyses in an attempt to predict the potential aerodynamic impact of the smart control surface on overall model forces and moments. Eight different control surface shapes were selected for study at Mach = 0.6, Reynolds number = 3.25 x 10(exp 6), and + 2 deg., 3 deg., 8 deg., and 10 deg.model angles-of-attack. For the baseline, undeflected control surface geometry, the CFD predictions and wind-tunnel results matched well. The agreement was not as good for the more complex aero-loaded control surface shapes, though, because of the inability to accurately predict those shapes. Despite these results, the NASA CFD study served as an important step in studying advanced control effectors.

Measurement of rotorcraft blade deformation using projection moire interferometry

Projection Moire interferometry (PMI) has been sued to obtain near instantaneous, quantitative blade deformation measurements of a generic rotorcraft model at several test conditions. These laser-based measurements provide quantitative, whole field, dynamic blade deformation profiles conditionally sampled as a function of rotor azimuth. The instantaneous nature of the measurements permits computation of the mean and unsteady blade deformation, blade bending, and twist. The PMI method is presented, and the image processing steps required to obtain quantitative deformation profiles from PMI interferograms are descried. Experimental results are provided which show blade bending, twist, and unsteady motion. This initial proof-of-concept test has demonstrated the capability of PMI to acquire accurate, full field rotorcraft blade deformation data.

Design, Fabrication, and Testing of SMA Enabled Adaptive Chevrons for Jet Noise Reduction

This study presents the status and results from an effort to design, fabricate, and test an adaptive jet engine chevron concept based upon embedding shape memory alloy (SMA) actuators in a composite laminate, termed a SMA hybrid composite (SMAHC). The approach for fabricating the adaptive SMAHC chevrons involves embedding prestrained Nitinol actuators on one side of the mid-plane of the composite laminate such that thermal excitation generates a thermal moment and deflects the structure. A glass-epoxy pre-preg/Nitinol ribbon material system and a vacuum hot press consolidation approach are employed. A versatile test system for control and measurement of the chevron deflection performance is described. Projection moire interferometry (PMI) is used for global deformation measurement and infrared (IR) thermography is used for 2-D temperature measurement and feedback control. A recently commercialized constitutive model for SMA and SMAHC materials is used in the finite element code ABAQUS to perform nonlinear static analysis of the chevron prototypes. Excellent agreement is achieved between the predicted and measured chevron deflection performance, thereby validating the design tool. Although the performance results presented in this paper fall short of the requirement, the concept is proven and an approach for achieving the performance objectives is evident.

DARPA/AFRL Smart Wing Phase 2 wind tunnel test results

Northrop Grumman Corporation built and twice tested a 30 percent scale wind tunnel model of a proposed uninhabited combat air vehicle under the DARPA/AFRL Smart Materials and Structures Development - Smart Wing Phase 2 program to demonstrate the applicability of smart control surfaces on advanced aircraft configurations. The model constructed was a full span, sting mounted model with smart leading and trailing edge control surfaces on the right wing and conventional, hinged trailing edge control surfaces on the left wing. Among the performance benefits that were quantified were increased pitching moment, increased rolling moment and improved pressure distribution of the smart wing over the conventional wing. This paper present an overview of the result from the wind tunnel test performed at NASA Langley Research Centers Transonic Dynamic Tunnel in March 2000 and May 2001. Successful results included: (1) improved aileron effectiveness at high dynamic pressures, (2) demonstrated improvements in lateral and longitudinal effectiveness with smooth contoured smart trailing edge over conventional hinged control surfaces, (3) chordwise and spanwise shape control of the smart trailing edge control surface, and (4) smart trailing edge control surface deflection rates over 80 deg/sec.

LiveView3D: Real Time Data Visualization for the Aerospace Testing Environment

This paper addresses LiveView3D, a software package and associated data visualization system for use in the aerospace testing environment. The LiveView3D system allows researchers to graphically view data from numerous wind tunnel instruments in real time in an interactive virtual environment. The graphical nature of the LiveView3D display provides researchers with an intuitive view of the measurement data, making it easier to interpret the aerodynamic phenomenon under investigation. LiveView3D has been developed at the NASA Langley Research Center and has been applied in the Langley Unitary Plan Wind Tunnel (UPWT). This paper discusses the capabilities of the LiveView3D system, provides example results from its application in the UPWT, and outlines features planned for future implementation. horough aerodynamic analysis of any proposed vehicle configuration requires a careful assessment and understanding of the off-body flow physics, on-body surface flow properties, and structural aeroelastic characteristics. Although computational fluid dynamics (CFD) and finite-element modeling (FEM) codes can now provide predictions of these aerodynamic characteristics, a significant portion of vehicle aerodynamic assessment is still accomplished by wind tunnel testing. A number of different optical diagnostic techniques currently exist for measuring the flow and structural properties of wind tunnel models under test 1 . Extracting knowledge from these extensive data sets, often gigabytes per test condition, requires efficient and revealing data visualization methods. Most data produced by currently available optical instrumentation techniques are processed off-line, and full analysis may not occur until weeks or months after the test. However, the cost of wind tunnel operations and the complexity of interrelated aerodynamic phenomena being investigated are pushing the requirement of real-time data visualization and analysis. Real-time data visualization can dramatically improve the knowledge and understanding of the physical processes and aerodynamic behavior occurring during a test. This knowledge and understanding can then be used to alter the test matrix to focus on conditions of interest, thus maximizing the test value while contributing to minimizing the test cost. The LiveView3D software and data visualization system has been developed to provide the ability to view data from wind tunnel instrumentation systems in an interactive virtual environment in real time. LiveView3D is an extension of the Virtual Diagnostics Interface (ViDI) technology 1 previously developed for pre-test planning and post-test data visualization. The primary distinction between ViDI and LiveView3D is that ViDI is a “usage methodology” of commercially available software, and LiveView3D is a custom-written software package that utilizes ViDI technology. ViDI is predominantly used for pre

Rapid technology assessment via unified deployment of global optical and virtual diagnostics

This paper discusses recent developments in rapid technology assessment resulting from an active collaboration between researchers at the Air Force Research Laboratory (AFRL) at Wright Patterson Air Force Base (WPAFB) and the NASA Langley Research Center (LaRC). This program targets the unified development and deployment of global measurement technologies coupled with a virtual diagnostic interface to enable the comparative evaluation of experimental and computational results. Continuing efforts focus on the development of seamless data translation methods to enable integration of data sets of disparate file format in a common platform. Results from a successful low-speed wind tunnel test at WPAFB in which global surface pressure distributions were acquired simultaneously with model deformation and geometry measurements are discussed and comparatively evaluated with numerical simulations. Intensity- and lifetime-based pressure-sensitive paint (PSP) and projection moire interferometry (PMI) results are presented within the context of rapid technology assessment to enable simulation-based R&D.

Modal analysis of an aircraft fuselage panel using experimental and finite-element techniques

The application of electro-optic holography (EOH) for measuring the center bay vibration modes of an aircraft fuselage panel under forced excitation is presented. The requirement of free-free panel boundary conditions made the acquisition of quantitative EOH data challenging since large scale rigid body motions corrupted measurements of the high frequency vibrations of interest. Image processing routines designed to minimize effects of large scale motions were applied to successfully resurrect quantitative EOH vibrational amplitude measurements from extremely noisy data. EOH and scanning laser doppler vibrometer results have been used to validate and update finite element models of the fuselage panel. Various modeling techniques were evaluated for characterization of the panel normal modes at frequencies up to 1000 Hz. These models are briefly described, and comparisons between computational predictions and experimental measurements are presented.

Design, fabrication, and testing of a SMA hybrid composite jet engine chevron

Control of jet noise continues to be an important research topic. Exhaust nozzle chevrons have been shown to reduce jet noise, but parametric effects are not well understood. Additionally, thrust loss due to chevrons at cruise suggests significant benefit from deployable chevrons. The focus of this study is development of an active chevron concept for the primary purpose of parametric studies for jet noise reduction in the laboratory and technology development to leverage for full scale systems. The active chevron concept employed in this work consists of a laminated composite structure with embedded shape memory alloy (SMA) actuators, termed a SMA hybrid composite (SMAHC). The actuators are embedded on one side of the middle surface such that thermal excitation generates a moment and deflects the structure. A brief description of the chevron design is given followed by details of the fabrication approach. Results from bench top tests are presented and correlated with numerical predictions from a model for such structures that was recently implemented in MSC.Nastran and ABAQUS. Excellent performance and agreement with predictions is demonstrated. Results from tests in a representative flow environment are also presented. Excellent performance is again achieved for both open- and closed-loop tests, the latter demonstrating control to a specified immersion into the flow. The actuation authority and immersion performance is shown to be relatively insensitive to nozzle pressure ratio (NPR). Very repeatable immersion control with modest power requirements is demonstrated.