Determining the adverse aerodynamic effects due to ice accretion often relies on dry-air wind-tunnel testing of artificial, or simulated, ice shapes. Recent developments in ice-accretion documentation methods have yielded a laser-scanning capability that can measure highly three-dimensional features of ice accreted in icing wind tunnels. The objective of the current study was to evaluate the aerodynamic accuracy of ice-accretion simulations generated from laser-scan data. Tests were conducted in the NASA Glenn Icing Research Tunnel, where ice accretions were measured with laser scanning before the molding process. Aerodynamic performance testing was conducted at the University of Illinois low-speed wind tunnel at a Reynolds number of 1.8 x 10(6) and a Mach number of 0.18 with an airfoil model designed to accommodate artificial ice shapes. The ice-accretion molds were used to fabricate one set of artificial ice shapes from polyurethane castings. The laser-scan data were used to fabricate another set of artificial ice shapes using rapid-prototype manufacturing. The iced-airfoil results with both sets of artificial ice shapes were compared to evaluate the aerodynamic simulation accuracy. The data showed that the laser-scan and rapid-prototype manufacturing approach was capable of replicating small ice features within the reported accuracies of the laser-scan measurement and rapid-prototyping methods, thus providing a new capability for high-fidelity ice-accretion documentation and artificial ice-shape fabrication for icing research.

A test was conducted at NASA Icing Research Tunnel to evaluate altitude scaling methods for thermal ice protection system. Two scaling methods based on Weber number were compared against a method based on the Reynolds number. The results generally agreed with the previous set of tests conducted in NRCC Altitude Icing Wind Tunnel. The Weber number based scaling methods resulted in smaller runback ice mass than the Reynolds number based scaling method. The ice accretions from the Weber number based scaling method also formed farther upstream. However there were large differences in the accreted ice mass between the two Weber number based scaling methods. The difference became greater when the speed was increased. This indicated that there may be some Reynolds number effects that isnt fully accounted for and warrants further study.

This report documents the data collected during the large wind tunnel campaigns conducted as part of the SUNSET project (StUdies oN Scaling EffecTs due to ice) also known as the Ice-Accretion Aerodynamics Simulation study: a joint effort by NASA, the Office National d'Etudes et Recherches Aerospatiales (ONERA), and the University of Illinois. These data form a benchmark database of full-scale ice accretions and corresponding ice-contaminated aerodynamic performance data for a two-dimensional (2D) NACA 23012 airfoil. The wider research effort also included an analysis of ice-contaminated aerodynamics that categorized ice accretions by aerodynamic effects and an investigation of subscale, low- Reynolds-number ice-contaminated aerodynamics for the NACA 23012 airfoil. The low-Reynolds-number investigation included an analysis of the geometric fidelity needed to reliably assess aerodynamic effects of airfoil icing using artificial ice shapes. Included herein are records of the ice accreted during campaigns in NASA Glenn Research Center's Icing Research Tunnel (IRT). Two different 2D NACA 23012 airfoil models were used during these campaigns; an 18-in. (45.7-cm) chord (subscale) model and a 72-in. (182.9-cm) chord (full-scale) model. The aircraft icing conditions used during these campaigns were selected from the Federal Aviation Administration's (FAA's) Code of Federal Regulations (CFR) Part 25 Appendix C icing envelopes. The records include the test conditions, photographs of the ice accreted, tracings of the ice, and ice depth measurements. Model coordinates and pressure tap locations are also presented. Also included herein are the data recorded during a wind tunnel campaign conducted in the F1 Subsonic Pressurized Wind Tunnel of ONERA. The F1 tunnel is a pressured, high- Reynolds-number facility that could accommodate the full-scale (72-in. (182.9-cm) chord) 2D NACA 23012 model. Molds were made of the ice accreted during selected test runs of the full-scale model in the IRT. From these molds, castings were made that closely replicated the features of the accreted ice. The castings were then mounted on the full-scale model in the F1 tunnel, and aerodynamic performance measurements were made using model surface pressure taps, the facility force balance system, and a large wake rake designed specifically for these tests. Tests were run over a range of Reynolds and Mach numbers. For each run, the model was rotated over a range of angles-of-attack that included airfoil stall. The benchmark data collected during these campaigns were, and continue to be, used for various purposes. The full-scale data form a unique, ice-accretion and associated aerodynamic performance dataset that can be used as a reference when addressing concerns regarding the use of subscale ice-accretion data to assess full-scale icing effects. Further, the data may be used in the development or enhancement of both ice-accretion prediction codes and computational fluid dynamic codes when applied to study the effects of icing. Finally, as was done in the wider study, the data may be used to help determine the level of geometric fidelity needed for artificial ice used to assess aerodynamic degradation due to aircraft icing. The structured, multifaceted approach used in this research effort provides a unique perspective on the aerodynamic effects of aircraft icing. The data presented in this report are available in electronic form upon formal approval by proper NASA and ONERA authorities.

Determining the adverse aerodynamic effects due to ice accretion often relies on dry-air wind-tunnel testing of artificial, or simulated, ice shapes. Recent developments in ice accretion documentation methods have yielded a laser-scanning capability that can measure highly three-dimensional features of ice accreted in icing wind tunnels. The objective of this paper was to evaluate the aerodynamic accuracy of ice-accretion simulations generated from laser-scan data. Ice-accretion tests were conducted in the NASA Icing Research Tunnel using an 18-inch chord, 2-D straight wing with NACA 23012 airfoil section. For six ice accretion cases, a 3-D laser scan was performed to document the ice geometry prior to the molding process. Aerodynamic performance testing was conducted at the University of Illinois low-speed wind tunnel at a Reynolds number of 1.8 x 10(exp 6) and a Mach number of 0.18 with an 18-inch chord NACA 23012 airfoil model that was designed to accommodate the artificial ice shapes. The ice-accretion molds were used to fabricate one set of artificial ice shapes from polyurethane castings. The laser-scan data were used to fabricate another set of artificial ice shapes using rapid prototype manufacturing such as stereolithography. The iced-airfoil results with both sets of artificial ice shapes were compared to evaluate the aerodynamic simulation accuracy of the laser-scan data. For four of the six ice-accretion cases, there was excellent agreement in the iced-airfoil aerodynamic performance between the casting and laser-scan based simulations. For example, typical differences in iced-airfoil maximum lift coefficient were less than 3% with corresponding differences in stall angle of approximately one degree or less. The aerodynamic simulation accuracy reported in this paper has demonstrated the combined accuracy of the laser-scan and rapid-prototype manufacturing approach to simulating ice accretion for a NACA 23012 airfoil. For several of the ice-accretion cases tested, the aerodynamics is known to depend upon the small, three dimensional features of the ice. These data show that the laser-scan and rapid-prototype manufacturing approach is capable of replicating these ice features within the reported accuracies of the laser-scan measurement and rapid-prototyping method; thus providing a new capability for high-fidelity ice-accretion documentation and artificial ice-shape fabrication for icing research.

Research has been conducted to better understand the phenomena involved during operation of an aircraft's thermal ice protection system under running wet icing conditions. In such situations, supercooled water striking a thermally ice-protected surface does not fully evaporate but runs aft to a location where it freezes. The effects of altitude, in terms of air pressure and density, on the processes involved were of particular interest. Initial study results showed that the altitude effects on heat energy transfer were accurately modeled using existing methods, but water mass transport was not. Based upon those results, a new method to account for altitude effects on thermal ice protection system operation was proposed. The method employs a two-step process where heat energy and mass transport are sequentially matched, linked by matched surface temperatures. While not providing exact matching of heat and mass transport to reference conditions, the method produces a better simulation than other methods. Moreover, it does not rely on the application of empirical correction factors, but instead relies on the straightforward application of the primary physics involved. This report describes the method, shows results of testing the method, and discusses its limitations.

A research plan is currently being implemented by NASA to develop and validate the use of a commercial laser scanner to record and archive fully three-dimensional (3-D) ice shapes from an icing wind tunnel. The plan focused specifically upon measuring ice accreted in the NASA Icing Research Tunnel (IRT). The plan was divided into two phases. The first phase was the identification and selection of the laser scanning system and the post-processing software to purchase and develop further. The second phase was the implementation and validation of the selected system through a series of icing and aerodynamic tests. Phase I of the research plan has been completed. It consisted of evaluating several scanning hardware and software systems against an established selection criteria through demonstrations in the IRT. The results of Phase I showed that all of the scanning systems that were evaluated were equally capable of scanning ice shapes. The factors that differentiated the scanners were ease of use and the ability to operate in a wide range of IRT environmental conditions.

The simulation of ice accretion on a wing or other surface is often required for aerodynamic evaluation, particularly at small scale or low-Reynolds number. While there are commonly accepted practices for ice simulation, there are no established and validated guidelines. The purpose of this article is to report the results of an experimental study establishing a high-fidelity, full-scale, iced-airfoil aerodynamic performance database. This research was conducted as a part of a larger program with the goal of developing subscale aerodynamic simulation methods for iced airfoils. Airfoil performance testing was carried out at the ONERA F1 pressurized wind tunnel using a 72-in. (1828.8-mm) chord NACA 23012 airfoil over a Reynolds number range of 4.5x10(exp 6) to 16.0 10(exp 6) and a Mach number range of 0.10 to 0.28. The high-fidelity, ice-casting simulations had a significant impact on the aerodynamic performance. A spanwise-ridge ice shape resulted in a maximum lift coefficient of 0.56 compared to the clean value of 1.85 at Re = 15.9x10(exp 6) and M = 0.20. Two roughness and streamwise shapes yielded maximum lift values in the range of 1.09 to 1.28, which was a relatively small variation compared to the differences in the ice geometry. The stalling characteristics of the two roughness and one streamwise ice simulation maintained the abrupt leading-edge stall type of the clean NACA 23012 airfoil, despite the significant decrease in maximum lift. Changes in Reynolds and Mach number over the large range tested had little effect on the iced-airfoil performance.

Factors external to the aircraft are often a significant causal factor in loss of control (LOC) accidents. In today s aviation world, very few accidents stem from a single cause and typically have a number of causal factors that culminate in a LOC accident. Very often the 'trigger' that initiates an accident sequence is an external environment factor. In a recent National Aeronautics and Space Administration (NASA) statistical analysis of LOC accidents, aircraft icing was shown to be the most common external environmental LOC causal factor for scheduled operations. When investigating LOC accident or incidents aircraft icing causal factors can be categorized into groups of (1) in-flight encounter with super-cooled liquid water clouds, (2) take-off with ice contamination, or (3) in-flight encounter with high concentrations of ice crystals. As with other flight hazards, icing induced LOC accidents can be prevented through avoidance, detection, and recovery mitigations. For icing hazards, avoidance can take the form of avoiding flight into icing conditions or avoiding the hazard of icing by making the aircraft tolerant to icing conditions. Icing detection mitigations can take the form of detecting icing conditions or detecting early performance degradation caused by icing. Recovery from icing induced LOC requires flight crew or automated systems capable of accounting for reduced aircraft performance and degraded control authority during the recovery maneuvers. In this report we review the icing induced LOC accident mitigations defined in a recent LOC study and for each mitigation describe a research topic required to enable or strengthen the mitigation. Many of these research topics are already included in ongoing or planned NASA icing research activities or are being addressed by members of the icing research community. These research activities are described and the status of the ongoing or planned research to address the technology needs is discussed

This paper describes a study performed to investigate how aerodynamic performance degradation progresses with time throughout an exposure to icing conditions. It is one of the first documented studies of the effects of ice contamination on aerodynamic performance at various points in time throughout an icing encounter. Both a 1.5 and 6 ft chord, two-dimensional, NACA-23012 airfoils were subjected to icing conditions in the NASA Icing Research Tunnel for varying lengths of time. At the end of each run, lift, drag, and pitching moment measurements were made. Measurements with the 1.5 ft chord model showed that maximum lift and pitching moment degraded more rapidly early in the exposure and degraded more slowly as time progressed. Drag for the 1.5 ft chord model degraded more linearly with time, although drag for very short exposure durations was slightly higher than expected. Only drag measurements were made with the 6 ft chord airfoil. Here, drag for the long exposures was higher than expected. Novel comparison of drag measurements versus an icing scaling parameter, accumulation parameter times collection efficiency was used to compare the data from the two different size model. The comparisons provided a means of assessing the level of fidelity needed for accurate icing simulation.

This report describes recent improvements in aerodynamic scaling and simulation of ice accretion on airfoils. Ice accretions were classified into four types on the basis of aerodynamic effects: roughness, horn, streamwise, and spanwise ridge. The NASA Icing Research Tunnel (IRT) was used to generate ice accretions within these four types using both subscale and full-scale models. Large-scale, pressurized windtunnel testing was performed using a 72-in.- (1.83-m-) chord, NACA 23012 airfoil model with high-fidelity, three-dimensional castings of the IRT ice accretions. Performance data were recorded over Reynolds numbers from 4.5 x 10(exp 6) to 15.9 x 10(exp 6) and Mach numbers from 0.10 to 0.28. Lower fidelity ice-accretion simulation methods were developed and tested on an 18-in.- (0.46-m-) chord NACA 23012 airfoil model in a small-scale wind tunnel at a lower Reynolds number. The aerodynamic accuracy of the lower fidelity, subscale ice simulations was validated against the full-scale results for a factor of 4 reduction in model scale and a factor of 8 reduction in Reynolds number. This research has defined the level of geometric fidelity required for artificial ice shapes to yield aerodynamic performance results to within a known level of uncertainty and has culminated in a proposed methodology for subscale iced-airfoil aerodynamic simulation.

Flowfield measurements were carried out on the upper surface of a GLC-305 airfoil configured with glaze and rime ice-shape simulations. The mean and root-mean-square fluctuation of the streamwise velocity were measured using a split-hot-film probe at several chordwise locations. These data were taken at three different angles of attack preceding stall for each iced-airfoil configuration at Reynolds numbers of 3.5 × 10 6 and 6.0 x 10 6 with Mach numbers of 0.12 and 0.21. The velocity measurements confirmed the presence of a large separation bubble downstream of the ice shapes. The separation bubbles for the glaze ice configuration were much larger than those for the rime ice case, resulting from the differences in the ice horn geometry. Other than the differences in size, the integral boundary-layer characteristics were very similar. Changes in Reynolds number did not significantly affect the separation bubble characteristics. However, a larger Mach number did result in a slightly larger separation bubble for the glaze ice case at α = 6 deg. The root-mean-square velocity distributions had peak values in the separated shear layer, downstream of transition, that compared well with previous work.

A computational investigation was performed to assess the effectiveness of Detached Eddy Simulation (DES) as a tool for predicting icing effects. The AVUS code, a public domain flow solver, was employed to compute solutions for an iced wing configuration using DES and steady Reynolds Averaged Navier-Stokes (RANS) equation methodologies. The wing section considered here was a business jet airfoil (GLC305) with a 22.5-minute glaze ice accretion (944-ice shape). The section was extruded to form a rectangular planform. The model was mounted between two walls so no tip effects were considered. The numerical results were validated by comparison with experimental data for the same configuration. The time-averaged DES computations showed some improvement in lift and drag results near stall when compared to steady RANS results. However, comparisons of the flow field details did not show the level of agreement suggested by the integrated quantities. More validation is needed to determine what role DES can play as part of an overall icing effects prediction strategy.

WIND, Fluent, and PowerFLOW were used to predict the lift, drag, and moment coefficients of a business-jet airfoil with a rime ice (rough and jagged, but no protruding horns) and with a glaze ice (rough and jagged end has two or more protruding horns) for angles of attack from zero to and after stall. The performance of the following turbulence models were examined by comparing predictions with available experimental data. Spalart-Allmaras (S-A), RNG k-epsilon, shear-stress transport, v(sup 2)-f, and a differential Reynolds stress model with and without non-equilibrium wall functions. For steady RANS simulations, WIND and FLUENT were found to give nearly identical results if the grid about the iced airfoil, the turbulence model, and the order of accuracy of the numerical schemes used are the same. The use of wall functions was found to be acceptable for the rime ice configuration and the flow conditions examined. For rime ice, the S-A model was found to predict accurately until near the stall angle. For glaze ice, the CFD predictions were much less satisfactory for all turbulence models and codes investigated because of the large separated region produced by the horns. For unsteady RANS, WIND and FLUENT did not provide better results. PowerFLOW, based on the Lattice Boltzmann method, gave excellent results for the lift coefficient at and near stall for the rime ice, where the flow is inherently unsteady.

For rime ice - where the ice buildup has only rough and jagged surfaces but no protruding horns - this study shows two dimensional CFD analysis based on the one-equation Spalart-Almaras (S-A) turbulence model to predict accurately the lift, drag, and pressure coefficients up to near the stall angle. For glaze ice - where the ice buildup has two or more protruding horns near the airfoil's leading edge - CFD predictions were much less satisfactory because of the large separated region produced by the horns even at zero angle of attack. This CFD study, based on the WIND and the Fluent codes, assesses the following turbulence models by comparing predictions with available experimental data: S-A, standard k-epsilon, shear-stress transport, v(exp 2)-f, and differential Reynolds stress.

Steady-state solutions of the Reynolds-averaged Navier-Stokes (RANS) equations were computed using the Colbalt flow solver for a constant-section, rectangular wing based on an extruded two-dimensional glaze ice shape. The one equation Spalart-Allmaras turbulence model was used. The results were compared with data obtained from a recent wind tunnel test. Computed results indicate that the steady RANS solutions do not accurately capture the recirculating region downstream of the ice accretion, even after a mesh refinement. The resulting predicted reattachment is farther downstream than indicated by the experimental data. Additionally, the solutions computed on a relatively coarse baseline mesh had detailed flow characteristics that were different from those computed on the refined mesh or the experimental data. Steady RANS solutions were also computed to investigate the effects of spanwise variation in the ice shape. The spanwise variation was obtained via a bleeding function that merged the ice shape with the clean wing using a sinusoidal spanwise variation. For these configurations, the results predicted for the extruded shape provided conservative estimates for the performance degradation of the wing. Additionally, the spanwise variation in the ice shape and the resulting differences in the flow fields did not significantly change the location of the primary reattachment.

Aerodynamic wind tunnel tests were conducted to study the effects of various ice accretions on the aerodynamic performance of a 36-inch chord, two-dimensional business jet airfoil. Eight different ice shape configurations were tested. Four were castings made from molds of ice shapes accreted in an icing wind tunnel. Two were made using computationally smoothed tracings of two of the ice shapes accreted in the icing tunnel. These smoothed profiles were then extended in the spanwise direction to form a twodimensional ice shape. The final two configurations were formed by applying grit to the smoothed ice shapes. The ice shapes resulted in as much as 48% reduction in maximum lift coefficient from that of the clean airfoil. Large increases in drag and changes in pitching moment were also observed. The castings and their corresponding smoothed counterparts yielded similar results. Little change in performance was observed with the addition of grit to the smoothed ice shapes. Changes in the Reynolds number (from 3×10 to 10.5×10) and Mach number (from 0.12 to 0.28) did not significantly affect the iced-airfoil performance coefficients.

An experiment was conducted in the Icing Research Tunnel (IRT) at NASA Glenn Research Center to obtain castings of ice accretions formed on a 28 deg. swept GLC-305 airfoil that is representative of a modern business aircraft wing. Because of the complexity of the casting process, the airfoil was designed with three removable leading edges covering the whole span. Ice accretions were obtained at six icing conditions. After the ice was accreted, the leading edges were detached from the airfoil and moved to a cold room. Molds of the ice accretions were obtained, and from them, urethane castings were fabricated. This experiment is the icing test of a two-part experiment to study the aerodynamic effects of ice accretions.