H. Harris Hamilton

Computational Aerothermodynamic Design Issues for Hypersonic Vehicles

A brief review of the evolutionary progress in computational aerothermodynamics is presented. The current status of computational aerothermodynamics is then discussed, with emphasis on its capabilities and limitations for contributions to the design process of hypersonic vehicles. Some topics to be highlighted include: (1) aerodynamic coefficient predictions with emphasis on high temperature gas effects; (2) surface heating and temperature predictions for thermal protection system (TPS) design in a high temperature, thermochemical nonequilibrium environment; (3) methods for extracting and extending computational fluid dynamic (CFD) solutions for efficient utilization by all members of a multidisciplinary design team; (4) physical models; (5) validation process and error estimation; and (6) gridding and solution generation strategies. Recent experiences in the design of X-33 will be featured. Computational aerothermodynamic contributions to Mars Path finder, METEOR, and Stardust (Comet Sample return) will also provide context for this discussion. Some of the barriers that currently limit computational aerothermodynamics to a predominantly reactive mode in the design process will also be discussed, with the goal of providing focus for future research.

X-33 Hypersonic Boundary Layer Transition

Boundary layer and aeroheating characteristics of several X-33 configurations have been experimentally examined in the Langley 20-Inch Mach 6 Air Tunnel. Global surface heat transfer distributions, surface streamline patterns, and shock shapes were measured on 0.013-scale models at Mach 6 in air. Parametric variations include angles-of-attack of 20-deg, 30-deg, and 40-deg; Reynolds numbers based on model length of 0.9 to 6.6 million; and body-flap deflections of 0, 10 and 20-deg. The effects of discrete and distributed roughness elements on boundary layer transition, which included trip height, size, location, and distribution, both on and off the windward centerline, were investigated. The discrete roughness results on centerline were used to provide a transition correlation for the X-33 flight vehicle that was applicable across the range of reentry angles of attack. The attachment line discrete roughness results were shown to be consistent with the centerline results, as no increased sensitivity to roughness along the attachment line was identified. The effect of bowed panels was qualitatively shown to be less effective than the discrete trips; however, the distributed nature of the bowed panels affected a larger percent of the aft-body windward surface than a single discrete trip.

Approximate Method for Calculating Heating Rates on Three-Dimensional Vehicles

An approximate method for calculating heating rates on three-dimensional vehicles at angle of attack is presented. The method is based on the axisymmetric analog for three-dimensional boundary layers and uses a generalized body-fitted coordinate system. Edge conditions for the boundary-layer solution are obtained from an inviscid flowfield solution, and because of the coordinate system used, the method is applicable to any blunt body geometry for which an inviscid flowfield solution can be obtained. The method is validated by comparing with experimental heating data and with thin-layer Navier-Stokes calculations on the shuttle orbiter at both wind-tunnel and flight conditions and with thin-layer Navier-Stokes calculations on the HL-20 at wind-tunnel conditions.

Inviscid Surface Streamlines and Heat Transfer on Shuttle-Type Configurations

A method is developed which calculates laminar, transitional, and turbulent heating rates on arbitrary blunt-nosed three-dimensional bodies at angle of attack in hypersonic flow. The geometry of the body may be specified analytically, or generated from a doubly cubic spline fit to coordinate points. Inviscid surface streamlines are calculated from Eulers equation using a prescribed pressure distribution. Laminar and turbulent heating rates are determined along a streamline by applying the axisymmetric analog to solutions of the axisymmetric boundary-layer equations. The location of the transition region may be specified optionally by geometric location, momentum thickness Reynolds number, or integrated unit Reynolds number along a streamline. Transitional heating rates are then calculated as a weighted average of the local laminar and turbulent values. Either ideal gas or equilibrium air properties may be used. Results are presented for blunted circular cones, and a typical delta-wing space shuttle orbiter at angle of attack. In comparison with experimental data, the present method was found to yield accurate laminar heating rates and reasonably accurate transitional and turbulent heating rates. The computer program developed to calculate the results presented herein requires only a few seconds of computing time per streamline on the CDC 6600 computer.

A review of some approximate methods used in aerodynamic heating analyses

It is pointed out that preliminary design and optimization studies for new aerospace vehicles require techniques which can calculate aerodynamic heating rates accurately and efficiently. The method employed to calculate the flow field depends to a large extent on the shape of the vehicle, Mach number, Reynolds number, and Knudsen number. In the case of the aero-assisted orbital transfer vehicle (AOTV), a substantial portion of the flight will be in the transitional regime between continuum and free molecule flow. The present paper discusses some approximate methods which have been used to calculate heating rates on high-speed vehicles. Attention is given to the stagnation point and leading edges, the downstream region, the axisymmetric analog, laminar and turbulent heating rates, transition heating rates, gas models, and three-dimensional applications.

Application of axisymmetric analog for calculating heating in three-dimensional flows

A rapid, approximate method has been developed for calculating the heating rates on three-dimensional vehicles such as the Space Shuttle Orbiter and other advanced reentry configurations. The method is based on the axisymmetric analogue for three-dimensional boundary layers. It uses information obtained from a three-dimensional inviscid flowfield solution, such as HALIS, to calculate inviscid surface streamlines along which approximate heating rates are calculated independent of what happens along other streamlines. Three-dimensional effects are included through the metric coefficient that describes the divergence or convergence of streamlines. Boundary-layer edge properties are obtained from the inviscid flowfield solution by interpolating in the inviscid flowfield at a distance equal to the boundary-layer thickness away from the wall. This accounts, approximately, for the variable boundary-layer edge entropy. Using this method, heating calculations can be made along a typical streamline in a few seconds. This method has been used to accurately predict heating rates for simple shapes such as a spherically blunted cone and more complex shapes such as the Shuttle Orbiter for a variety of wind-tunnel and flight conditions. A unique feature of the method is its ability to accurately predict heating rates on the Shuttle Orbiter wing.

Aerodynamic Heating on 3-D Bodies Including the Effects of Entropy-Layer Swallowing

A relatively simple method is presented to include the effects of entropy-layer swallowing in a method developed previously for calculating laminar, transitional, and turbulent heating rates on three-dimensional bodies in hypersonic flows. The boundary layer swallows the entropy layer when the boundary layer downstream of the nose region has entrained those streamlines which passed through the nearly normal part of the bow shock wave. The entropy at the edge of the boundary layer is then determined by equating the mass flow inside the boundary layer to that entering part of the bow shock wave. A new inviscid flowfield solution, which is an extension of Maslens axisymmetric method, is developed to calculate the three-dimensional shock shape and couple the inviscid solution with the viscous solution. The calculated heating rates compare favorably with Maynes theory and experimental data for blunted circular and elliptical cones at angles of attack. The effects of entropy layer swallowing on the calculated heating rates were small for laminar heating but large increases were noted for the turbulent heating rates. The computer program developed to calculate the results presented herein required only about 7 sec per streamline on the IM 370/165 computer.

X-33 Experimental Aeroheating at Mach 6 Using Phosphor Thermography

The goal of the NASA Reusable Launch Vehicle (RLV) technology program is to mature and demonstrate essential, cost effective technologies for next generation launch systems. The X-33 flight vehicle presently being developed by Lockheed Martin is an experimental Single Stage to Orbit (SSTO) demonstrator that seeks to validate critical technologies and insure applicability to a full scale RLV. As with the design of any hypersonic vehicle, the aeroheating environment is an important issue and one of the key technologies being demonstrated on X-33 is an advanced metallic Thermal Protection System (TPS). As part of the development of this TPS system, the X-33 aeroheating environment is being defined through conceptual analysis, ground based testing, and computational fluid dynamics. This report provides an overview of the hypersonic aeroheating wind tunnel program conducted at the NASA Langley Research Center in support of the ground based testing activities. Global surface heat transfer images, surface streamline patterns, and shock shapes were measured on 0.013 scale (10-in.) ceramic models of the proposed X-33 configuration in Mach 6 air. The test parametrics include angles of attack from -5 to 40 degs, unit Reynolds numbers from 1x106 to 8x106/ft, and body flap deflections of 0, 10, and 20 deg. Experimental and computational results indicate the presence of shock/shock interactions that produced localized heating on the deflected flaps and boundary layer transition on the canted fins. Comparisons of the experimental data to laminar and turbulent predictions were performed. Laminar windward heating data from the wind tunnel was extrapolated to flight surface temperatures and generally compared to within 50 deg F of flight prediction along the centerline. When coupled with the phosphor technique, this rapid extrapolation method would serve as an invaluable TPS design tool.

Discrete Roughness Effects on Shuttle Orbiter at Mach 6

Discrete roughness boundary layer transition results on a Shuttle Orbiter model in the NASA Langley Research Center 20-Inch Mach 6 Air Tunnel have been reanalyzed with new boundary layer calculations to provide consistency for comparison to other published results. The experimental results were previously obtained utilizing the phosphor thermography system to monitor the status of the boundary layer via global heat transfer images of the Orbiter windward surface. The size and location of discrete roughness elements were systematically varied along the centerline of the 0.0075-scale model at an angle of attack of 40 deg and the boundary layer response recorded. Various correlative approaches were attempted, with the roughness transition correlations based on edge properties providing the most reliable results. When a consistent computational method is used to compute edge conditions, transition datasets for different configurations at several angles of attack have been shown to collapse to a well-behaved correlation.

Development of a Boundary Layer Properties Interpolation Tool in Support of Orbiter Return to Flight

A new tool was developed to predict the boundary layer quantities required by several physics-based predictive/analytic methods that assess damaged Orbiter tile. This new tool, the Boundary Layer Property Prediction (BLPROP) tool, supplies boundary layer values used in correlations that determine boundary layer transition onset and surface heating-rate augmentation/attenuation factors inside tile gouges (i.e. cavities). BLPROP interpolates through a database of computed solutions and provides boundary layer and wall data (delta, theta, Re(sub theta)/M(sub e), Re(sub theta)/M(sub e), Re(sub theta), P(sub w), and q(sub w)) based on user input surface location and free stream conditions. Surface locations are limited to the Orbiter s windward surface. Constructed using predictions from an inviscid w/boundary-layer method and benchmark viscous CFD, the computed database covers the hypersonic continuum flight regime based on two reference flight trajectories. First-order one-dimensional Lagrange interpolation accounts for Mach number and angle-of-attack variations, whereas non-dimensional normalization accounts for differences between the reference and input Reynolds number. Employing the same computational methods used to construct the database, solutions at other trajectory points taken from previous STS flights were computed: these results validate the BLPROP algorithm. Percentage differences between interpolated and computed values are presented and are used to establish the level of uncertainty of the new tool.