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This paper presents the results of a computational fluid dynamics validation exercise using the General Aerodynamic Simulation Program (GASP) code for vehicles under consideration for the X-38 program. The scope of the exercise involved simulation and comparison with wind tunnel aeroheating and aerodynamic data in the hypersonic regime. In addition, simulations were performed and results are presented for the full-scale flight vehicle along an expected re- entry trajectory.

This paper summarizes the arc jet test results of the Mars Exploration Rover (MER) Silicone Impregnated Reusable Ceramic Ablator (SIRCA) Transverse Impulse Rocket System (TIRS) Cover test series in the Panel Test Facility (PTF) at NASA Ames Research Center (ARC). NASA ARC performed aerothermal environment analyses, TPS sizing and thermal response analyses, and arc jet testing to evaluate the MER SIRCA TIRS Cover design and interface to the aeroshell structure. The primary objective of this arc jet test series was to evaluate specific design details of the SIRCA TIRS Cover interface to the MER aeroshell under simulated atmospheric entry heating conditions. Four test articles were tested in an arc jet environment with various sea] configurations. The test condition was designed to match the predicted peak flight heat load at the gap region between the SIRCA and the backshell TPS material, SLA-561S, and resulted in an over-test (with respect to heat flux and heat load) for the apex region of the SIRCA TIRS Cover. The resulting pressure differential was as much as twenty times that predicted for the flight case, depending on the location, and there was no post-test visual evidence of over-heating or damage to the seal, bracket, or backshell structure. The exposed titanium bolts were in good condition at post-test and showed only a small amount of oxidation at the leading edge locations. Repeatable thermocouple data were obtained and SIRCA thermal response analyses were compared to applicable thermocouple data. For the apex region of the SIRCA TIRS Cover, a one-dimensional thermal response prediction proved overly conservative, as there were strong multi-dimensional conduction effects evident from the thermocouple data. The one-dimensional thermal response prediction compared well with the thermocouple data for the leading edge "lip" region at the bolt location. In general, the test results yield confidence in the baseline seal design to prevent hot gas ingestion at the bracket and composite aeroshell structure interface.

A proposed Mars Smart Lander is designed to reach the surface via lifting-body atmospheric entry (alpha = 16 deg) to within 10 km of the target site. CFD (computational fluid dynamics) predictions of the forebody aeroheating environments are given for a direct entry from a 2005 launch. The solutions were obtained using an 8-species gas in thermal and chemical nonequilibrium with a radiative-equilibrium wall temperature boundary condition. Select wind tunnel data are presented from tests at NASA Langley Research Center. Turbulence effects are included to account for both smooth body transition and turbulence due to heatshield penetrations. Natural transition is based on a momentum-thickness Reynolds number value of 200. The effects of heatshield penetrations on turbulence are estimated from wind tunnel tests of various cavity sizes and locations. Both natural transition and heatshield penetrations are predicted to cause turbulence prior to the nominal trajectory peak heating time. Laminar and turbulent CFD predictions along the trajectory are used to estimate heat rates and loads. The predicted peak turbulent heat rate of 63 W/sq cm on the heatshield leeward flank is 70% higher than the laminar peak. The maximum integrated heat load for a fully turbulent heat pulse is 38% higher than the laminar load on the heatshield nose. The predicted aeroheating environments with uncertainty factors will be used to design a thermal protection system.

Computational fluid dynamics (CFD) is used to simulate the wake flow and afterbody heating of the Project Fire II ballistic reentry to Earth at 11.4 km/sec. Laminar results are obtained over a portion of the trajectory between the initial heat pulse and peak afterbody heating. Although non-catalytic forebody convective heating results are in excellent agreement with previous computations, initial predictions of afterbody heating were about a factor of two below the experimental values. Further analysis suggests that significant catalysis may be occurring on the afterbody heat shield. Computations including finite-rate catalysis on the afterbody surface are in good agreement with the data over the early portion of the trajectory, but are conservative near the peak afterbody heating point, especially on the rear portion of the conical frustum. Further analysis of the flight data from Fire II shows that peak afterbody heating occurs before peak forebody heating, a result that contradicts computations and flight data from other entry vehicles. This result suggests that another mechanism, possibly pyrolysis, may be occurring during the later portion of the trajectory, resulting in less total heat transfer than the current predictions.

35 years later, the Project FIRE II ballistic reentry to Earth at a nominal velocity of 11.4 km/s remains one of the best sources of heating data for the design of sample return capsules. The data from this flight experiment encompass both the thermochemical non-equilibrium and equilibrium flow regimes and include measurements of both radiative and total heating on the forebody and afterbody. Because of this, a number of researchers have performed computational fluid dynamics (CFD) simulations of the forebody of the FIRE II entry vehicle, with generally good results. In particular, Olynick et. al. coupled a Navier-Stokes solver (GIANTS) with a radiation code (NOVAR) and showed excellent agreement in surface heat transfer over the FIRE II trajectory between 1634 and 1651 seconds (77 km to 37 km). However, in most cases the primary motivation of the previous work was to understand and model the coupling between shock layer radiation and aerothermodynamics, and thus the simulations concentrated on the forebody flow only. To our knowledge there have been no prior published attempts to reproduce the afterbody heating data. However, an understanding of this data is critical to our efforts to design the next generation of Earth and planetary entry vehicles and to assess our need for additional flight data.

Recent advances in computational power enable computational fluid dynamic modeling of increasingly complex configurations. A review of grid generation methodologies implemented in support of the computational work performed for the X-38 and X-33 are presented. In strategizing topological constructs and blocking structures factors considered are the geometric configuration, optimal grid size, numerical algorithms, accuracy requirements, physics of the problem at hand, computational expense, and the available computer hardware. Also addressed are grid refinement strategies, the effects of wall spacing, and convergence. The significance of grid is demonstrated through a comparison of computational and experimental results of the aeroheating environment experienced by the X-38 vehicle. Special topics on grid generation strategies are also addressed to model control surface deflections, and material mapping.

Much of the ground based testing of advanced thermal protection system (TPS) components for the X33 program is done in arc-heated wind tunnels such as those located in the Arc-Jet Complex at NASA Ames Research Center. These facilities are capable of simulating the high temperature, chemically reacting flow environment experienced by the vehicle during flight. This allows one to test critical design issues such as maximum reuse temperatures, seals, gaps, and increases in heating due to interfaces between different materials. Computational fluid dynamics (CFD) has evolved to the point where it now can be used in the vehicle design process for accurate and timely prediction of trajectory based aerothermal heating environments for re-entry vehicles. It can also be used for simulation of the flow environments in ground based facilities such as arcjets. By utilization of the same CFD code and solution methodology, the important differences between ground test and flight may be quantified. The goal of this paper is to utilize CFD to provide validated simulations of the flow environment in the NASA-Ames semi elliptic nozzle arcjet facilities. The validation of the ground simulations will come From comparison to existing calibration data. Specific tests in support of the X33 TPS test program will ilso be simulated. In this manner, the differences between the ground test simulation and the flight environment can be identified for a measure of ground test to flight traceability.

Grid generation issues relating to the simulation of the X33 aerothermal environment using the GASP code are explored. Required grid densities and normal grid stretching are discussed with regards to predicting the fluid dynamic and heating environments with the desired accuracy. The generation of volume grids is explored and includes discussions of structured grid generation packages such as GRIDGEN, GRIDPRO and HYPGEN. Volume grid manipulation techniques for obtaining desired outer boundary and grid clustering using the OUTBOUND code are examined. The generation of the surface grid with the required surface grid with the required surface grid topology is also discussed. Utilizing grids without singular axes is explored as a method of avoiding numerical difficulties at the singular line.

This paper describes the test techniques and results from the National Aerospace Plane Government Work Package 53, the Ames Integrated Mixing Hypersonic Engine (AIMHYE) Scramjet Test program conducted in the NASA Ames 16-Inch Combustion Driven Shock Tunnel. This was a series of near full-scale scramjet combustor tests with the objective to obtain high speed combustor and nozzle data from an engine with injector configurations similar to the NASP E21 and E22a designs. The experimental test approach was to use a large combustor model (80-100% throat height) designed and fabricated for testing in the semi-free jet mode. The conditions tested were similar to the "blue book" conditions at Mach 12, 14, and 16. GWP 53 validated use of large, long test time impulse facilities, specifically the Ames 16-Inch Shock Tunnel, for high Mach number scramjet propulsion testing an integrated test rig (inlet, combustor, and nozzle). Discussion of key features of the test program will include: effects of the 2-D combustor inlet pressure profile; performance of large injectors' fueling system that included nozzlettes, base injection, and film cooling; and heat transfer measurements to the combustor. Significant instrumentation development and application efforts include the following: combustor force balance application for measurement of combustor drag for comparison with integrated point measurements of skin friction; nozzle metric strip for measuring thrust with comparison to integrated pressure measurements; and nonintrusive optical fiber-based diode laser absorption measurements of combustion products for determination of combustor performance. Direct measurements will be reported for specific test article configurations and compared with CFD solutions.

Simultaneous multiple path measurements of temperature and H2O concentration will be presented for the AIMHYE test entries in the NASA Ames 16-Inch Shock Tunnel. Monitoring the progress of high temperature chemical reactions that define scramjet combustor efficiencies is a task uniquely suited to nonintrusive optical diagnostics. One application strategy to overcome the many challenges and limitations of nonintrusive measurements is to use laser absorption spectroscopy coupled with optical fibers. Absorption spectroscopic techniques with rapidly tunable lasers are capable of making simultaneous measurements of mole fraction, temperature, pressure, and velocity. The scramjet water absorption diagnostic was used to measure combustor efficiency and was compared to thrust measurements using a nozzle force balance and integrated nozzle pressures to develop a direct technique for evaluating integrated scramjet performance. Tests were initially performed with a diode laser tuning over a water absorption feature at 1391.7 nm. A second diode laser later became available at a wavelength near 1343.3 nm covering an additional water absorption feature and was incorporated in the system for a two-wavelength technique. Both temperature and mole fraction can be inferred from the lineshape analysis using this approach. Additional high temperature spectroscopy research was conducted to reduce uncertainties in the scramjet application. The lasers are optical fiber coupled to ports at the combustor exit and in the nozzle region. The output from the two diode lasers were combined in a single fiber, and the resultant two-wavelength beam was subsequently split into four legs. Each leg was directed through 60 meters of optical fiber to four combustor exit locations for measurement of beam intensity after absorption by the water within the flow. Absorption results will be compared to 1D combustor analysis using RJPA and nozzle CFD computations as well as to data from a nozzle metric balance measuring thrust and integrated pressure measurements along the length of the nozzle. Assessment of its value as a combustor performance evaluation tool will be conducted.

Proposed configurations for the next generation of transatmospheric vehicles will rely on air breathing propulsion systems during all or part of their mission. At flight Mach numbers greater than about 7 these engines will operate in the supersonic combustion ramjet mode (scramjet). Ground testing of these engine concepts above Mach 8 requires high pressure, high enthalpy facilities such as shock tunnels and expansion tubes. These impulse, or short duration facilities have test times on the order of a millisecond, requiring high speed instrumentation and data systems. One such facility ideally suited for scramjet testing is the NASA-Ames 16-Inch shock tunnel, which over the last two years has completed a series of tests for the NASP (National Aero-Space Plane) program at simulated flight Mach numbers ranging from 12-16. The focus of the experimental programs consisted of a series of classified tests involving a near-full scale hydrogen fueled scramjet combustor model in the semi-free jet method of engine testing whereby the compressed forebody flow ahead of the cowl inlet is reproduced (see appendix A). The AIMHYE-1 (Ames Integrated Modular Hypersonic Engine) test entry for the NASP program was completed in April 1993, while AIMHYE-2 was completed in May 1994. The test entries were regarded as successful, resulting in some of the first data of its kind on the performance of a near full scale scramjet engine at Mach 12-16. The data was distributed to NASP team members for use in design system verification and development. Due to the classified nature of the hardware and data, the data reports resulting from this work are classified and have been published as part of the NASP literature. However, an unclassified AIAA paper resulted from the work and has been included as appendix A. It contains an overview of the test program and a description of some of the important issues.

Results are presented of the first high-speed propulsion-related experiments performed in the NASA-Ames 16-Inch Shock Tunnel, designed to simulate combustor inlet conditions at approximately Mach 14. Results demonstrate the capability of the tunnel for high-speed propulsion testing and yield data on the performance of 30-deg flush wall injectors tested in the tunnel. The experimental results are compared with those of a CFD analysis.

Flow characteristics of NASA's 16-Inch Shock Tunnel are determined for purposes of providing hypersonic propulsion simulation capability. The key tunnel operating parameters are the incident shock speed and reservoir pressure and enthalpy. Flow characteristics of concern are the nozzle exit pressure, temperature, Mach number, Reynolds number, chemical composition, and flow uniformity. Surface mounted gages (for pressure and heat transfer) and nonintrusive optical flow diagnostics (emission and absorption spectroscopy and holographic interferometry) are used to verify tunnel conditions. Experimental measurements are used to validate computational analysis for predicting facility performance, and CFD is used to interpret the free stream optical diagnostic measurements.

A laser absorption flow diagnostic application has been developed at the NASA Ames 16-inch Shock Tunnel for purposes of measuring the thermochemical state of OH in flow environments of interest. Research objectives include the investigation of high temperature, low pressure chemistry pertinent to scramjet combustors and high altitude flight. The system can be operated in either the fixed frequency mode or in the rapid wavelength scanning mode to measure species mole fraction and temperature. Emission diagnostics have been employed to determine shock tunnel flow quality and assist in the proper application of the diagnostic and its data interpretation. Rotational lines in the OH system were probed in the expanding facility nozzle flow, and time-resolved measurements of temperature and mole fraction are provided.

The application of dark central ground interferometry in a supersonic wind tunnel is presented. Examples of this method as a quantitative flow visualization technique for several types of supersonic flowfields are presented. Theoretical work is presented regarding the effects of vibrations and filter size. The method is shown to be an inexpensive, easy to use tool for situations requiring interferograms for flow visualization.