The Aeronautics Research Mission Directorate at NASA is developing and applying tools to enable future technologies towards sustainable flight. Aircraft icing has been identified as a potential barrier to entry into service for innovative designs necessitating improvements to computational ice accretion tools. NASA is developing the Glenn Icing Computational Environment (GlennICE) to address deficiencies in the computational modeling capabilities of previously developed ice accretion solvers. To benchmark and improve the ability to model highly three-dimensional ice accretion, high quality validation data against experimental data is required. The CRM65 Midspan Hybrid geometry was previously tested at the NASA Icing Research Tunnel to generate experimental data for swept wing geometries typical for commercial transport aircraft. As a part of a 2018 icing test campaign, experimental data characterizing the relationship between ice accretion time and ice mass growth was obtained and can be leveraged for use in validation of computational tools. The desire for computational ice accretion solvers to predict ice shapes profiles accreted experimentally has often overshadowed the comparison to the mass and bulk volume of ice accreted. To address this deficiency, an analysis is presented in which GlennICE is applied to simulations of the CRM65 Midspan Hybrid model tested in the NASA Icing Research Tunnel. Results from the computational fluid dynamics simulations compared favorably to the experimental pressure coefficient data, thus validating the modeling setup. The experimental data showed excellent repeatability for the 15.0 minute accretion time. The comparisons between the experimental and computational ice mass over time showed good agreement up to 10.0 minutes after which the ice mass was underpredicted. The experimental ice mass was largely linear with some nonlinear data. The bulk volume of ice accreted experimentally compared well to GlennICE for the scanned ice shapes and mean combined cross section ice shapes, but was underpredicted for the maximum combined cross section ice shapes at longer accretion times. The experimental minimum combined cross section, mean combined cross section, and maximum combined cross section profiles when compared to GlennICE show good agreement for the mean combined cross section up to 15.0 minutes. The analyses show that with a single-shot method, GlennICE currently underpredicts the ice mass for longer accretion times, is not able to match the bulk volume of the maximum combined cross section due to dominating scallop features, and future work is required to generate a more generalized ice bulk density model.

In-flight icing is an important safety issue and is a factor that affects aircraft design and performance. Newer regulations are driving a need for improvements in airframe and engine icing simulation capability. Experimental data is required for the development of icing physics models and simulation validation. This paper presents the analysis of the ice crystal icing data subset from tests conducted in 2022 at the NASA Icing Research Tunnel that studied both supercooled liquid and ice-crystal icing. The test article that was utilized replicated 3D geometrical features of an inter-compressor duct and strut region of a turbofan engine. The surfaces of the Simulated Inter-compressor Duct Research Model (SIDRM) can be heated to simulate the warm surfaces of the turbofan inter-compressor duct. The test article is instrumented with pressure taps, heaters, heat flux gauges, and thermocouples, while a 3D laser scanner, cameras, and a weighing scale to measure ice mass were utilized to characterize the icing behavior. The aim of these tests was to generate ice accretions on the SIDRM test article under well-characterized icing conditions. To that end, ice crystal cloud characterization tests were conducted that provided cloud property values at the test section. The ice crystal accretion tests investigated how different test condition parameters impacted ice accretion size, location, and characteristics ( such as physical attributes). A key finding was that a sufficiently high surface heat flux at the leading edge can provide a continuous supply of liquid melt to critical accretion zones downstream, resulting in elevated ice mass accretions. Another key finding was that warmer heater settings in critical accretion zones can suppress ice accretion. These findings are consistent with icing behavior observed in full-scale engine icing tests conducted previously at the NASA Glenn Research Center. Test runs investigating the contribution of liquid melt generated at the leading edge found that the melt can be transported downstream to critical accretion regions in two forms, via runback and splash. The form of melt supplied downstream affected accretion behavior and features. Sharkteeth-shaped ice accretions were generated at certain test conditions, a physical attribute that has been observed in full-scale engine icing tests. The ice accretion data will be used to develop and validate 3D computational engine icing tools, such as GlennICE, that predictively assesses the onset and growth of ice. One of the goals of the sponsoring NASA project is to develop simulation models and tools that can assist in the design and certification of engines for flight in icing conditions in a cost-effective way.

In-flight icing is an important consideration that affects aircraft design, performance, certification and safety. Newer regulations combined with increasing demand to reduce fuel burn, emissions and noise are driving a need for improvements in icing simulation capability. To that end, this paper presents the results of additional ice accretion testing conducted in the NASA Icing Research Tunnel in January 2022 with a large swept wing section typical of a modern commercial transport. The model was based upon a section of the Common Research Model wing at the 64% semispan station with a streamwise chord length of 136 in. The test conditions were developed with an icing scaling analysis to generate similar conditions for a small median volumetric diameter (MVD) = 25 μm cloud and a large MVD = 110 μm cloud. A series of tests were conducted over a range of total temperature from -23.8 °C to -1.4 °C with all other conditions held constant. Another series of tests explored cloud MVD variations from 50 μm to 230 μm while holding constant certain scaling parameters. The variation in ice mass and scanned ice volume across repeat conditions was approximately 50% lower than the uncertainty in the cloud MVD and liquid water content. The measured ice mass and volume calculated from the 3D scans were used to compute the mass to volume ratio that is sometimes referred to as ice density or void fraction. When the ice volume based on the ice shape maximum combined cross section was used to determine this ratio, the resulting values were in the range of 240 to 455 kg/m3. This is consistent with analogous values previously reported in the literature. The ice shape mass and volume increased with MVD from 50 to 230 μm at fixed values of the scaling parameters. The ice mass to volume ratio was approximately constant for all of the cases which showed that the accreted mass and volume increased at approximately the same rate. These results demonstrate the significance of cloud MVD on ice shape mass and volume.

A research program was conducted to evaluate the effectiveness of icing tunnel hybrid model design. A hybrid design is where the full-scale leading edge of a wing section is maintained only to a certain percentage of the local chord, while the aft section of the model is redesigned into a shortened or truncated planform. An initial study was conducted in 2020 where the ice shape geometries on a full-chord length version of the swept CRM65 wing model were compared to those from the hybrid version of CRM65 that were obtained in the NASA Icing Research Tunnel in 2015. The results were reported in a 2021 paper. For most test conditions, the overall size and shape of the ice shapes compared well. However, the ice shapes from the full-chord model were generally slightly smaller than those from the hybrid model. A follow-on test was conducted in 2022 and obtained ice shapes on both full-chord and hybrid wing models during the same test campaign to eliminate the differences in the tunnel spray nozzle configuration and calibration as a cause for the differences observed during the previous investigation. The ice shapes obtained on the full-chord model compared much better to those obtained on the hybrid model during the 2022 test, with nearly identical cross sections and ice mass values generally within 5%.

This paper describes the cloud characterization and icing tests conducted with a 3D heated test article in Winter/Spring 2022 at the NASA Icing Research Tunnel. The intent is to present analyzed results from these recently conducted tests in a future technical paper. The test article, whose geometry is representative of an inter-compressor duct and strut region of a turbofan engine, has been designed and constructed to study the physics of supercooled water icing and ice crystal icing. The surfaces of the Simulated Inter-compressor Duct Research Model (SIDRM) can be heated to simulate the warm surfaces of the turbofan inter-compressor duct. The test article is instrumented with heaters, heat flux gauges, and thermocouples, while a 3D laser scanner, cameras, a scale to measure ice mass, and other instruments will aid in characterizing the icing behavior. The aim of these tests is to generate ice accretions on the SIDRM test article under well-characterized conditions. To that end, a suite of instruments was utilized to characterize the ice crystal clouds at the test section in a separate test series. The icing measurements collected during the SIDRM model tests will be used to develop and validate 3D computational engine icing tools, such as GlennICE, that predictively assesses the onset and growth of ice. One of the goals of the sponsoring NASA project is to develop simulation models and tools that can assist in the design and certification of engines for flight in icing conditions in a cost‑effective way.

A research program was conducted to evaluate the effectiveness of a hybrid model design for icing tunnel. A hybrid design is where the full-scale leading edge of a wing section is maintained only to a certain percentage of the local chord, while the aft section of the model is redesigned into a shortened or truncated planform. This is done when the models become too large relative to the wind tunnel. Ice shape geometries on a full-chord length and hybrid version of the swept CRM65 wing model were obtained in the NASA Icing Research Tunnel and compared. For most test conditions, the overall size and shape of the ice shapes compared well. On the main part of the ice shape, the hybrid model ice shapes had larger chordwise extent, resulting in wider ice shapes. For the scallop ice shapes, the ice shape heights at the attachment line location were identical. For conditions that produced rime ice, hybrid model ice shapes were larger overall, even at the attachment line location. The only location where there was more ice on the full chord model was on the lower surface, downstream of where the hybrid model no longer had full-scale leading edge. For the test conditions where ice mass measurements were acquired for both models, the full-chord model ice shapes had 11-22% less ice mass than for the hybrid wing ice shapes. Further investigation is needed in order determine the cause of the differences between the full-chord and hybrid models.

In-flight icing is an important consideration that affects aircraft design, performance and safety. Newer regulations combined with increasing demand to reduce fuel burn, emissions and noise are driving a need for improvements in icing simulation capability. To that end, this paper presents the results of ice accretion testing conducted in the NASA Icing Research Tunnel on a large swept wing section typical of a modern commercial transport. The model was based upon a section of the Common Research Model wing at the 64% semispan station with a streamwise chord length of 136 in. The test conditions were developed with an icing scaling analysis to generate similar conditions for a small MVD = 25 μm and a large MVD = 110 μm. A series of tests were conducted over a range of total temperature from -23.8 ˚C to -1.4 ˚C with all other conditions held constant. The results for the small MVD cloud conditions were consistent with previous work and showed the changing ice morphology from rime ice at colder temperatures to highly 3D scallop ice in the range of -8.7 ˚C to -3.8 ˚C. The results for the large MVD cloud conditions exhibited some differences in the ice accretion morphology from the small MVD conditions. Scallop-like ice features were observed at a total temperature of -3.8˚C. The large MVD ice accretion at lower temperatures tended to be smoother than the corresponding ice accretion for small MVD. The thickness of the main ice shape tended to be larger for the small MVD conditions compared to the corresponding large MVD ice shape while the latter had more ice farther downstream. The measured ice mass was approximately equal between the corresponding small and large MVD ice shapes up to a freezing fraction of 0.6. For higher freezing fraction, the large MVD ice shapes weighed more. Cloud MVD variation from 50 μm to 230 μm while holding the scaling parameters constant resulted in very minor differences in the ice shapes, mostly in the upper and lower surface chordwise extents. Ice volume was computed from 3D scan data and used to calculate a ratio of ice mass to volume. The resulting values were in the range of 240 to 455 Kg/m3. While this is consistent with analogous values previously reported in the literature, more data are needed to determine a specific trend in this ratio as a function of freezing fraction and the corresponding physical phenomena governing this trend. This work has resulted in a significant experimental database of ice accretion for small and large MVD conditions applicable to large-scale swept wings.

Aerodynamic assessment of icing effects on swept wings is an important component of a larger effort to improve three-dimensional icing simulation capabilities. An understanding of ice-shape geometric fidelity on iced-wing aerodynamics and the associated flowfield features are needed to guide the development and validation of ice-accretion simulation tools. To this end, wind-tunnel testing was carried out for 8.9% and 13.3% scale semispan wing models based upon the Common Research Model airplane configuration. Various levels of geometric fidelity of an artificial ice shape representing a glaze-ice accretion on a swept wing were investigated. The highest fidelity artificial ice shape reproduced all of the three-dimensional features associated with the glaze ice accretion. The lowest fidelity artificial ice shapes were simple, spanwise-varying horn ice geometries intended to represent the maximum ice thickness on the wing upper surface. The results presented in this paper show that the addition of grit roughness to some lower-fidelity artificial ice shapes resulted in favorable lift and pitching moment comparisons to the wing with the highest fidelity artificial ice shape. In the range of 4.3 to 7.4 deg. angle of attack, surface oil flow visualization and pressure data show that the wing with the two lower fidelity simulations clearly demonstrated a leading edge vortex dominated flowfield, referred to as type I. For the wing with the high fidelity ice shape, the flowfield at lower angles of attack was characterized by streamwise vorticity flow referred to as type II. Between 6.4 and 7.4 deg. angle of attack, the type II flow structures was significantly altered and gave way to the type I leading edge vortex. This means that for angles of attack 7.4 deg. and higher, the wing with all three configurations exhibited the same type of flowfield. This helps to explain why there is reasonably good agreement in the lift and pitching moment coefficients among these configurations.

The effect of geometric fidelity on the aerodynamics of a swept wing with a “scallop” ice shape was studied. Three geometric fidelity versions of the ice shape were studied. The High Fidelity ice shape maintained all of the highly 3D features of the scallop shape. The 3D Smooth ice shape was smoothly lofted over the High Fidelity shape in order to eliminate all of the local 3D feature. The third ice shape was the 3D Smooth ice shape with roughness grit attached to the surface. The two 3D Smooth versions of the ice shape exhibited a flowfield characterized by a leading edge separation bubble that rolled into a spanwise running vortex. The surface pressure data showed classic leading edge separation bubbles that are observed on 2D airfoils with leading edge horn ice shapes. The High Fidelity ice shape exhibited a flowfield characterized by streamwise vortices that formed downstream of the ice shape. The streamwise vortices observed downstream of the High Fidelity ice shape appeared to reduce the size of the separation suction peak observed downstream of the 3D Smooth ice shapes. This reduced the lift for the High Fidelity ice shape, when compared to the 3D Smooth ice shapes. However, these streamwise vortices may have allowed the flow to remain attached longer and slightly increased the stall angle of attack, even though the maximum lift was lower.

An important consideration for swept-wing ice shapes is the level of geometric fidelity required to accurately capture the aerodynamics. One way to help make the task of addressing this more manageable is to organize the ice shapes into a small number of classifications. These classifications are done by grouping similar ice shape geometries that also have similar iced wing aerodynamics. Ice shape classifications for airfoils are more mature and are reviewed as an example. Swept wing ice shape classifications are based on the well-established airfoil classifications and here five classifications are proposed: leading-edge roughness, streamwise ice, 3D leading-edge horn, highly 3D leading-edge horn and spanwise ridge. Recent data on swept wing icing aerodynamics is used to develop and support this classification. The development, or suppression, of the leading-edge separation vortex on swept wings without a leading-edge device is seen to be key in the classification of the highly 3D leading-edge horn.

Understanding the aerodynamic impact of swept-wing ice accretions is a crucial component of the design of modern aircraft. Computer-simulation tools are commonly used to approximate ice shapes, so the necessary level of detail or fidelity of those simulated ice shapes must be understood relative to high-fidelity representations of the ice. Previous tests were performed in the NASA Icing Research Tunnel to acquire high-fidelity ice shapes. From this database, full-span artificial ice shapes were designed and manufactured for both an 8.9%-scale and 13.3%-scale semispan wing model of the CRM65 which has been established as the full-scale baseline for this swept-wing project. These models were tested in the Walter H. Beech wind tunnel at Wichita State University and at the ONERA F1 facility, respectively. The data collected in the Wichita St. University wind tunnel provided a low-Reynolds number baseline study while the pressurized F1 facility produced data over a wide range of Reynolds and Mach numbers with the highest Reynolds number studied being approximately Re = 11.9×106. Past work focused on only three different fidelity variations for ice shapes based on multiple icing conditions. This work presents a more detailed investigation into several fidelity representations of a single highly three-dimensional scallop ice accretion. Sensitivity to roughness size and application technique on a low-fidelity smooth ice shape is described. The data indicate that the aerodynamic performance is not especially sensitive to the grit variations. An ice accretion code was also used to generate ice shapes for aerodynamic testing and comparisons. These ice shapes have a general appearance like the low-fidelity smooth ice shapes, but in this case, the computer-generated ice shape is significantly smaller. As such, the impact of that ice shape on the aerodynamic performance of the wing is reduced compared to the smooth ice shape based on the icing experiment for those same conditions. Spanwise discontinuities were also introduced to a low-fidelity ice shape in an attempt to quantify the impact of those variation in the high-fidelity ice shape. While the lift data indicate good agreement between the high-fidelity ice shapes and the low-fidelity ice shapes with spanwise discontinuities, a closer investigation of the data suggests potential, significant differences in the flowfield. These results were similar at both facilities over the wide range of test conditions utilized.

Artificial ice shapes of various geometric fidelity were tested on a wing model based on the Common Research Model. Low Reynolds number tests were conducted at Wichita State University’s Walter H. Beech Memorial Wind Tunnel utilizing an 8.9% scale model, and high Reynolds number tests were conducted at ONERA’s F1 wind tunnel utilizing a 13.3% scale model. Several identical geometrically-scaled ice shapes were tested at both facilities, and the results were compared at overlapping Reynolds and Mach numbers. This was to ensure that the results and trends observed at low Reynolds number could be applied and continued to high, near-flight Reynolds number. The data from Wichita State University and ONERA F1 agreed well at matched Reynolds and Mach numbers. The lift and pitching moment curves agreed very well for most configurations. This confirmed results from previous tests with other ice shapes that indicated the data from the low Reynolds number tests could be used to understand iced-swept-wing aerodynamics at high Reynolds number. This allows ice aerodynamics testing to be performed at low Reynolds number facilities with much lower operating costs and generate results that are applicable to flight Reynolds number.

This paper studied the aerodynamic effects of a single scalloped ice accretion and two lower fidelity ice-shape simulations. These data were compared to the aerodynamics of a clean 8.9% scale CRM65 semispan wing model at a Reynolds number of 1.6 x 10(exp 6). The clean wing experienced an aggressive, tip-first stall and showed a small, strong leading-edge vortex at lower angle-of-attack while the iced cases showed larger, seemingly weaker leading-edge vortices at similar angles. The size of these vortices is larger for the low-fidelity ice shape. The stall pattern for the iced cases was also tip-first, but more gradual than the clean wing. The high-fidelity ice shape produced streamwise flow features over the upper surface of the wing due to flow moving through gaps that exist in the ice shape geometry that disrupted the formation of the leading-edge vortices, changing the aerodynamics of the wing. These gaps do not exist in the low-fidelity shape. The low-fidelity scallop ice shape was non-conservative in its aerodynamic penalties compared to the full high-fidelity case.

Aerodynamic assessment of icing effects on swept wings is an important component of a larger effort to improve three-dimensional (3D) icing simulation capabilities. An understanding of ice-shape geometric fidelity and Reynolds and Mach number effects on the iced-wing aerodynamics is needed to guide the development and validation of ice-accretion simulation tools. To this end, wind tunnel testing was carried out for a 13.3-percent-scale semispan wing based upon the Common Research Model airplane configuration. The wind tunnel testing was conducted at the Office National d’Etudes et de Recherches Aerospatiales (ONERA) F1 pressurized wind tunnel with Reynolds numbers of 1.6 x 10(exp 6) to 11.9 x 10(exp 6 ) and Mach numbers of 0.09 to 0.34. Five different configurations were investigated using fully 3D, high-fidelity artificial ice shapes that maintain nearly all of the 3D ice-accretion features documented in prior icing wind tunnel tests. These large, leading-edge ice shapes were nominally based upon airplane holding in icing conditions scenarios. For three of these configurations, lower fidelity simulations were also built and tested. The results presented in this paper show that while Reynolds and Mach number effects are important for quantifying the clean-wing performance, there is very little to no effect for an iced wing with 3D, high-fidelity artificial ice shapes or 3D smooth ice shapes with grit roughness. These conclusions are consistent with the large volume of past research on iced airfoils. However, some differences were also noted for the associated stalling angle of the iced swept wing and for various lower fidelity versions of the leading-edge ice accretion. More research is planned to further investigate the key features of ice-accretion geometry that must be simulated in lower fidelity versions in order to capture the essential aerodynamics.

Understanding the aerodynamic impact of swept-wing ice accretions is a crucial component of the design of modern aircraft. Computer-simulation tools are commonly used to approximate ice shapes, so the necessary level of detail or fidelity of those simulated ice shapes must be understood relative to high-fidelity representations of the ice. Previous tests were performed in the NASA Icing Research Tunnel to acquire high-fidelity ice shapes. Some of those ice shapes are based on aircraft certification requirements. From this database, full-span artificial ice shapes were designed and manufactured for both an 8.9%-scale and 13.3%-scale semispan wing model of the CRM65 which has been established as the full-scale baseline for this swept-wing project. These models were tested in the Walter H. Beech wind tunnel at Wichita State University and at the ONERA (Office national d'etudes et de recherches aerospatiales) F1 facility, respectively. The data collected in the Wichita State University wind tunnel provided a low-Reynolds number baseline study while the pressurized F1 facility produced data over a wide range of Reynolds and Mach numbers with the highest Reynolds number studied being approximately Re = 11.9 by 10 (sup 6). Three different fidelity representations were created based on three different icing conditions. Lower-fidelity ice shapes were created by lofting a smooth ice shape between cross-section cuts of the high-fidelity ice shape. Grit roughness was attached to this smooth ice shape as another fidelity variant. The data indicates that the geometric fidelity of the ice shapes resulted in significant differences in lift and drag. These results were similar at both facilities over the wide range of test conditions utilized.

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.

Low-Reynolds number testing was conducted at the 7 ft x 10 ft Walter H. Beech Memorial Wind Tunnel at Wichita State University to study the aerodynamic effects of ice shapes on a swept wing. A total of 17 ice shape configurations of varying geometric detail were tested. Simplified versions of an ice shape may help improve current ice accretion simulation methods and therefore aircraft design, certification, and testing. For each configuration, surface pressure, force balance, and fluorescent mini-tuft data were collected and for a selected subset of configurations oil-flow visualization and wake survey data were collected. A comparison of two ice shape geometries and two configurations with simplified geometric detail for each ice shape geometry is presented in this paper.

Roughness on aircraft ice accretions is very important to the overall ice accretion process and to the resulting degradation in aircraft aerodynamic performance. Roughness enhances the local convection leading to more rapid ice accumulation rates, and roughness generates local flow perturbations that lead to higher skin friction. This paper presents 1) a review of the developments in ice shape three-dimensional laser scanning developed at NASA Glenn, 2) a review of the approach of McClain and Kreeger employed to characterize ice roughness evolution on an airfoil surface, and 3) a review of the experimental efforts that have been performed over the last five years to characterize, scale, and model ice roughness evolution physics.

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.