Flow Control Applications: NASA/TM-2020-220436
Flow Control Applications: NASA/TM-2020-220436
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NASA/TM-2020-220436
Dennis M. Bushnell
Langley Research Center, Hampton, Virginia
Israel Wygnanski
University of Arizona, Tucson, Arizona
January 2020
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Dennis M. Bushnell
Langley Research Center, Hampton, Virginia
Israel Wygnanski
University of Arizona, Tucson, Arizona
January 2020
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Abstract
Flow control has a long history with many successes across a plethora of applications.
This report addresses the characteristics of the approaches that are actually used, why they are
used, the many approaches that are not used, and why. Analysis indicates ways forward to
increase applicability/usefulness, and efficiency of flow control research. Overall, greater and
more effective progress in flow control requires utilization of far more detailed information early
in the research process regarding application details and requirements.
Introduction
Flow control subsumes all types of technical flow control including laminar flow control,
mixing enhancement, separated flow control, vortex control, turbulence control, heat transfer
control, favorable wave interference, designer fluids and much more. Also included is the vast
preponderance of extant industrial flow control technology which involves valves and fluidics, for
which there is immense literature and technology including active control. The vision for
designer fluid mechanics includes, for example, the enablement of improved high lift, vectored
thrust, drag reduction (e.g. viscous, form, drag-due-to-lift), signature reduction, enhanced
combustion, reduced noise and pollution, improved flight/engine controls, reduced buffet, flutter
and fatigue, heat transfer control and a host of manufacturing, process and application specific
benefits.
Types of Fluids Controlled – Gas, Liquid, Plasma, Multi-Phase, Newtonian, Non-Newtonian, and
Designer Fluids
Types of Flows – 2-D, 3-D, Entire Speed Range, Laminar, Transitional, Turbulent, Attached,
Separated, Vortical, Shear Layers, Jets, Wakes, Free Surfaces, Steady, Unsteady, Shock
Waves, and Electromagnetic (EM)
Econometrics –Cost(s), potential profit, ancillary side effects, liability, market timeliness,
protectability, novelty, availability, complexity, distribution system, risk, regulatory issues,
productivity, market pull, and competition
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Safety/Environmental – Weather, vortex hazard, stall/spin, flutter, fatigue, reliability,
crashworthiness, emissions, and acoustics
Flow control approaches utilized in nature include shark dermal denticles, swept tapered
tips, wing tip feathers, cactus barrels, grooved shells, swordfish/marlin sword, gill efflux, and
fairings
Sample Flow Control Approaches Under Study and Development for Many Decades
Include:
Suction laminar flow control, circulation control, mission adaptive wing, several wing tip
approaches for wake vortex control and/or drag due to lift reduction, jet vortex generators,
vortex flap, suction separation control, active compressor stall control, microbubble turbulent
drag reduction, phase locked active wave cancellation, spanwise blowing for vortex lift,
transverse wall motions, and plasma control
An examination of these lists and the previous discussion herein suggests the following
features of a useful flow control approach: Simple and inexpensive in many cases, retrofittable
in some cases, passive/rigid (thus far), reliable/simulatable in ground facilities, and well
understood and proven.
7
Some Illustrative Example of Flow Control Visions vs. Reality
Example Remaining Issues for Hybrid Laminar Flow Control (HLFC) Include:
Insects, lack of a low disturbance large scale, high Reynolds number transonic tunnel,
complexity, leading edge device effectiveness, cost/reliability/maintainability, manufacturability,
fatigue life, and risk
Over the years, attempts were made to utilize heated body laminar flow control in
hydrodynamic applications. The approach worked well in tow tanks but not at sea. Studies
indicated that the various particulates in the water column tripped the flow. Yet another
instantiation of real-world conditions, this time in the environment, having a first order effect on
usability of flow control approaches. Similar real world (flight) effects upon suction LFC in the
swept wing x-21 experiments included a requirement for better than 50-mile visibility at high
altitudes to avoid laminar flow degradation due to ice cloud particulates. Additional flight issues
included acoustic disturbances from the suction system, the propulsion system, and the
turbulent fuselage boundary layer, as well as rain/heavy clouds, residual roughness, and
insects.
Vortex Control
The diversity and importance of longitudinal vortex control applications are extraordinary.
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Examples of Vortex Control Applications:
Submarine hull/sail “necklace” vortices (e.g. noise reduction, effects on control surfaces,
drag and propulsion), architectural aerodynamics, wake vortex hazard, turbomachinery
optimization, drag due to lift reduction, buffet/wing rock, noise reduction, heat transfer
augmentation/reduction, chemical engineering writ large, turbulence/mixing control, scouring,
energy separation, benthic oxygenation, and sediment control
Well-known aeronautical examples include: LEX [wing leading edge extensions], geometric
discontinuities utilized on fighter aircraft (e.g. F-16, F-18) which provide vortex lift and partially
attached lee-surface wing flow for enhanced maneuverability over a wide range of angles of
attack
Canards are used on all current European combat airplanes whose main wing has a
delta shape and is swept back at approximately 60o. The tip vortices emanating from the
canards have a large effect on the pressure distribution over the wing as may be seen on figure
1, where pressure sensitive paint is used on an airplane model of the Kfir, an F-21 that is a
variant of the French Mirage 5 that used the J-79 US made engine and canard. The test was
carried out at the University of Arizona and demonstrated the effects of the canard on the flow.
It contributed to the leading-edge vortex that is commonly present at these sweep angles,
particularly when the leading-edge curvature is large. The strengthening of the leading-edge
vortex increases the lift of the wing and provides a sufficient nose-up pitching moment that
alleviated the need for a horizontal stabilizer or an inflection at the trailing edge of wing’s airfoil
section. The incidence of the canard can vary independently of the airplane, thus providing the
adequate vortex strength at each attitude.
The Chinese Chengdu J-20 combat airplane has a movable (variable sweep) canard
that makes the canard more versatile.
Figure 1: Pressure sensitive paint wind tunnel study of the Kfir aircraft
Over the years, various alternative proposals of the active variety (e.g. moveable
geometry, blowing, suction, etc.) have been put forward, researched, and even, in some cases,
flown. Thus far, these active approaches have not been extensively applied. In the 1970s,
NASA worked a series of fixes to the wake vortex hazard problem and conducted flight tests on
a 747 aircraft. The general observation was that differences in detailed geometry and Reynolds
number between flight and the then available ground tests were responsible for the often large
laboratory-to-flight discrepancies. This provides clear support for the assertion cited previously
that adequate ground simulation at near flight conditions is essential, in this case to even sort
out the applicable physics, at least part of which was the curvature-induced Rayleigh
stabilization of the vortex core. Typical required separation distances between “heavy” and light
aircraft observed in the (unmodified) low Reynolds number ground tests were the order of half
or less those observed in the (unmodified) flight case. That is, the ground tests did not represent
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the base flight state correctly. Similar shortfalls in vortex and vortex control have also been
observed during marine, especially submarine, applications.
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Drag Due to Lift (DDL) Reduction
Drag due to lift is a major portion (40% to 45%) of aircraft cruise drag and 90% of takeoff
drag due to the requisite high lift levels. The obvious and well used approaches for reduction
include increased span, elliptic load distribution, winglets, and distributing lift vertically (e.g. bi
planes). There is a plethora of additional DDL reduction approaches, some with considerable
research heritage and some more speculative. The tip flow is 3-D and the extant flow angularity
can be utilized to either extract thrust or power. Alternatives include formation flying, reduced
vehicle weight, tip blowing, rotating tips, porous tips, wing tip engines, joined wing-tail, ring
wings, tip sails, vortex diffuser vane, tip turbines and swept back tapered tips, among others.
Several of these require systems level changes in structures/configuration for
enablement of such as wing tip engines, ring wings, and joined wing-tail. In general, and
curiously, as opposed to the major research efforts focused upon viscous drag reduction, the
efforts on drag due to lift reduction has been much less and, aside from mostly improved
winglets, not much application. DDL reduction appears to be a major opportunity area for flow
control going forward, including study of what has been found to improve lift and reduce wake
vortex hazard.
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thin stream of liquid water forward or projecting energy upstream. All of these “point” the shock
and reduce shock drag as well as heating.
Figure 2: The different spreading rates db/dx of mixing layers versus velocity ratio
λ= (U1-U2)/(U1+U2) representing the two streams creating the classical self-preserving,
turbulent mixing layer. The various symbols represent different experimental setups.
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The idea was pursued at numerous laboratories (e.g. NASA (95); Georgia Tech (94); IIT
(95), & industry (96)), and its validity was demonstrated on two airborne vehicles: a “Pioneer”
UAV in 1995 (97) and on the XV-15 tilt rotor airplane in 2003 (98]. A blower and a rotary valve
powered the active flow control (AFC) system in the Pioneer experiment, oscillating a jet that
emerged over a simple flap system. It increased the lift of the vehicle while requiring a relatively
small input of momentum coefficient (Cµ<1%). The test on the XV-15 was much more
extensive. It used 52 electromagnetic actuators that provided the required zero mass flux
periodic actuation. The actuators were placed in individual bays near the leading edge of the
flaps and emitted their oscillations through a segmented narrow slot. They reduced the
download created by the rotor wakes on the airplane in hover by enabling the flap to be
deflected at an angle that exceeded the natural separation angle by 15o. Coincidentally, the
download alleviation was approximately 17% as was the increase in the Pioneer’s lift, although
the configurations and flight test conditions were different.
The “Achilles Heel” of these tests were the actuators which were heavy and needed
maintenance. Various actuator types were considered (e.g. plasma actuators, piezo-electric,
mechanical, shape memory alloys, etc.) but none were satisfactory until the rediscovery of the
fluidic oscillators (often referred to as the sweeping jet actuators), that almost doubled the
download alleviation on the V-22 model. The potential use of these fluidic oscillators is attractive
because they are small, have no moving parts, and the air supply required by them is relatively
small as well. They can be easily integrated into a wing or a flap. The jets that they emit sweep
from one side of the nozzle to the other, therefore interacting periodically with different regions
of the flow to be controlled. The fluidic oscillators were developed during the 1950s at the Harry
Diamond Research Laboratories and used in analog computers and fluidic amplifiers. They are
currently used in automobile windshield washers, shower heads, and irrigation systems. Since
these commercial applications involve water, the effects of compressibility were not seriously
addressed in the past but this gap in knowledge was recently filled (99, 100)
The use of sweeping jets in the laboratory provided the impetus to put AFC into practice.
The most obvious and least risky application is the vertical tail (or stabilizer) of a twin-engine
airplane whose size is determined by the eventuality of an engine power loss during takeoff and
low speed climb. The vertical tail represents a large surface that is hardly used under normal
flight conditions, but it is indispensable during an “engine out” emergency, and is needed during
crosswind takeoff and landing. Although seldom used to its full capability, its presence adds
drag and weight to the aircraft, thus increasing its fuel consumption. Active flow control (AFC)
devices that delay flow separation over a highly deflected rudder may enable a smaller vertical
tail to provide the control authority needed during emergency. The purpose of the experiment
was to establish the efficacy of a system that uses fluidic oscillators at the rudder hinge. It broke
new ground in AFC applications because of the large sweep back of the vertical tail and its
relatively low aspect ratio. The natural flow direction over a typical rudder or a flap of a swept
back wing is dominated by the spanwise velocity because the chordwise flow decelerates as it
approaches the trailing edge, thus providing the Kutta-Joukowski condition. Consequently, a
small jet emanating from a point source is able to stop the natural spanwise flow and redirect it
downstream along the chord (101). In this sense a jet acts like a flexible fence or a jet curtain
and it may be more effective than the large fences currently seen on swept back wings. Initial
experiments on typical vertical tail models suggested that very few small jets located near the
rudder hinge can provide a large increment of lift (side force exceeding 20%). A collective input
momentum of Cμ ≈ 0.1% enabled sparsely distributed jets to redirect the surface-flow and
prevent flow reversal thus delaying separation over the rudder.
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Figure 3: The change of the side force coefficient with cmuat the highest rudder deflection angle when
various numbers of actuators were used at NFAC and a typical sweeping jet actuator.
The full-scale tests at the National Full-Scale Aerodynamics Complex (NFAC) (102, 103)
confirmed the concept of the fluidic fence but did not attempt to develop it further or optimize it.
The purpose of these tests was to prove the viability of active separation control at high
Reynolds number (Re) prior to demonstrating it on a Boeing 757 aircraft in flight (104). There
were many limitations imposed on the test that precluded a true development of the fluidic fence
concept. The test article used was an actual vertical tail that was removed from a mothballed
airplane. Its maximum rudder deflection was limited to the existing airplane range of 30o and it
was not modified. There were cut-outs in the rudder that accommodated the rudder deflection
mechanisms and those were blocked for a very short time to evaluate their impact on the flow
field. These constraints could be relaxed if the tests were to focus on development of a novel
AFC technology rather than fulfilling an arbitrary success criterion. Figure 3 presents the change
in the side force coefficient normalized by its baseline value as a function of Cμ at the highest
rudder deflection angle. It was noted that even a single actuator improved the control authority
of the rudder by approximately 9% relative to the measured and predicted baseline value,
suggesting that a nozzle whose total area was 1/8 in2 square can affect a wing whose area is
half a million times larger. This cannot be an issue of classical separation control because it
is impossible for a single wall-jet or even three or five of them to cover a substantial surface
area of the rudder. Since the purpose of this experiment was to control separation at high
rudder deflection angle and its success criterion for a demonstrative test flight was
14
predetermined, the discovery of the “fluidic fence” was not recognized by the sponsor nor
was it pursued any further. The CFD support proved to be a challenge. It precisely predicted
the baseline results but there were no tools in existence to simulate the time dependent flow
exiting the actuators and interacting with the three-dimensional turbulent boundary layer that
was either partly or totally separated. Large CFD effort carried out recently simulated the
extensive use of actuation on the rudder quite correctly (105, 106). Based on the predetermined
success criterion, a 31-actuator array configuration was chosen for the test flight because it
resulted in a 20% increase in side force at a side-slip angle of 7.5o. A TUI-Boeing 757-200
ecoDemonstrator was flown in the spring of 2015 (104). Although the flight test was considered
a resounding success, the critics pointed at a heat exchanger located below the APU, mocking
the achievement. Two years later it was shown that hotter sweeping jets were more effective
than colder ones and the jet flow cooled so rapidly that it did not pose a problem to the rudder
structure (102). Flow cones (tufts) placed on the rudder were photographed by a chase plane
and shown for reference (104).
The flight test pictures [Fig. 4] confirmed the observations made at NFAC and at the Lucas
wind tunnel at Caltech, showing how the rudder flow was redirected by the actuation. Pilot
feedback and analysis of the flight data proved the effectiveness of AFC, because a smoother
single engine flight was attained that was coupled to enhanced rudder control authority. It
resulted in NASA claiming an increase in the AFC Technology Readiness Level (TRL) from 3 to
6. However, the research on the vertical tail was stopped without providing a road map for future
optimization and system integration of AFC into the vertical tail or other control surfaces on an
airplane.
Figure 5 Possible installation of Fischer micro-turbo-compressor in the vertical tail of a 757 aircraft
(107)
Double Fuselage
Conventionally, double fuselage/multi-body aircraft have been employed to provide
span-load distribution and accrue the associated structural weight benefits (reduced wing
bending moment) without going all the way to a “blended wing body”/span loader configuration
(i.e. providing such benefits via “conventional” technology). Total aircraft drag is also reduced,
primarily due to favorable effects on drag due to lift. An advanced double fuselage approach
could attempt to delete the conventional outer wing panels and only retain a largely
unswept/long chord wing section between the fuselages. This requires prodigious drag due to lift
reduction, a requirement which can be addressed via design of the wing tip fuselages as wing-
tip “end plates” and the individual fuselage empennage as “winglets” (i.e. the tails become
thrusting surfaces in the presence of the wing vorticity wrapping around the fuselage(s)). For
this case, the “midwing” can become the site of the gear (to allow use of conventional runways),
with engines “buried” at the rear of the fuselages to accrue the benefits of “boundary layer
ingestion” and drag due to lift reduction, with extensive (natural/suction) laminar flow enabled by
the largely unswept “midwing.” Spanwise and localized ahead of the neutral curve heating strips
in the wing leading edge region would enable, from theory and experiment, longer regions of
laminar flow. The approach essentially converts the wing surface downstream of the neutral
curve into a “cooled region” as far as the incoming (upstream heated) flow is concerned and for
these speeds, in unswept flows, cooling is stabilizing. A major payoff would accrue from making
the fuselages detachable/interchangeable to provide a civilian “skytrain” with enhanced
productivity. The midwing portion which does all the “flying” could be in the air nearly “around
the clock” with interchangeable freighter and/or passenger modules, thereby nearly doubling the
productivity/duty cycle and the “return on investment.” Such an approach would allow a
restructuring of the airline capital investment, with the airlines “owning” their fuselages and
leasing the “midwing” from a “rent-a-wing” company. Obviously, military versions could have
cargo, troop, and refueling fuselages--providing a quantum jump in military flexibility and
productivity.
Spanwise wavy wings deduced from whale pectoral fin turbucules for improved lift and
possibly wake vortex mitigation and DDL reduction [Ref. 109]
A “Grim Wheel,” a flow turned disk just ahead of the internal inlet on a fuselage base
engine swallowing the fuselage boundary layer to reduce the inlet flow distortion [Ref.
110]
Water injection into the jet exhaust shear layer during takeoff to reduce takeoff jet noise
via mitigation of the causative jet turbulence, would also both increase thrust and obviate
the cruise weight and drag of the takeoff acoustics mitigation mixer-ejector approach for
SSTs
The Lobert Windmill, placing a windmill ahead of the air vehicle to extract energy, reduce
the boundary layer external velocity and thereby skin friction on the vehicle; the
extracted energy is carried to the rear where it is deposited in the vehicle wake,
producing thrust to partially obviate the drag produced by the energy extraction [Ref. 111
]
For ships or submersibles, extract phyto and zoo plankton from the cooling water and
cultivate on board drag reducing polymer to obviate having to load the requisite polymer
needed throughout the voyage
Continuous curvature, continuous 2nd derivative surfaces to minimize vortex production;
useful to reduce the self-noise on sonar domes and to mitigate hull bilge vortices which
reduce propulsion efficiency and create noise. Also can minimize lee side vortices on
aircraft
Turbulence tailoring/control in the combustor of gas turbine engines tailored to improve
the performance of downstream turbine stages
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Stopped rotor VTOL, a two bladed large rotor turned by tip fans to obviate a tail rotor.
Once aloft, to cruise efficiently, rotor is stopped, becomes the wing. Necessary to rapidly
morph the leading/trailing edges of one of the rotors at that point so both rotors are
facing the right way. The tip fans become part of the propulsion system for cruise and
reduce DDL. A quiet, efficient VTOL with good cruise efficiency [Refr. 112]
For SSTs, flow separation control at cruise to enable full inclusion of the many inviscid
performance enhancements now only partially employed due to flow separation,
including leading edge thrust, lift carryover onto the fuselage, carrying more lift on the
upper surface, and controlling the shock‐boundary layer interactions for parasol wing
designs
Concluding Remarks
Research and Development (R&D) of fixed geometry flow control approaches is still
occurring, notably the studies of the hump-back whale pectoral fin leading edge turbucles for
greater lift and possibly wake vortex hazard and DDL reduction.
Recent apparent breakthroughs in the laboratory regarding large net turbulent boundary
layer drag reduction via plasma actuators to induce spanwise motions (65) has, if proven, major
implications going forward.
There is a plethora of potential systems level flow control enablements, several positing
major benefits.
Boundary layer control by blowing enabled combat jet airplanes of the 1950s and 1960s
to operate from shorter runways by increasing their lift coefficient at low speeds. The concepts
of boundary layer and circulation control evolved at that time, however, blowing was never
considered interactively with other aerodynamic design parameters and it was always applied
after the design was frozen. The purpose of blowing boundary layer control was to supplement
the momentum loss in the boundary layer and it required a large momentum input to reduce the
landing speed by 30mph (e.g. F-104). A novel approach to AFC emerged after it was
recognized that turbulent flows are susceptible to instabilities that can naturally be amplified by
the flow itself. This enabled a small input level (of order ε) to and provide an output of order
unity, thus numerous interacting instabilities were exploited in “simple” two dimensional mean
flows and were even demonstrated in flight on a tilt rotor airplane (the XV-15). More recently the
focus has been 3D flows on swept wings where one has to maintain trim (i.e. keep the pitching
moment constant) over large range of lift coefficients. There is a need to augment the
effectiveness of control surfaces through the use of AFC, and in some situations to entirely
replace the traditional control surfaces by AFC. Experiments carried out on tailless aircraft
models indicate that dynamic tailoring of AFC in terms of momentum input and its location and
orientation, provides elegant solutions to problems plaguing such configurations. The research
on such configurations is ongoing, with attention being paid to the many real world metrics in
order to avoid blind alleys that caused ideas to fail.
The real-world metrics should be considered throughout the R&D process for flow
control, from initial ideation through the entire process to application. The flow control R&D
journey over many decades now is littered with the carcasses of approaches that were not, for
various reasons, suitable for the real-world. A way to make flow control R&D much more
effective, efficient, and timely is to do upfront, initial intel – market, application, utilization,
technical, competitive intelligence - and utilize such knowledgeability for the entire investigative
process from ideation/the decision of which approaches to study, through research and into
application. Experience indicates such efforts would be efficacious for R&D in the large, for
nearly all purposes, to increase the efficiency and cost effectiveness of R&D investments.
21
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14. ABSTRACT
Flow control, aka “Designer Fluid Mechanics,” has a long history with many successes across a plethora of applications. This report
addresses the characteristics of the approaches that are actually used, why they are used, the many approaches that are not used, and
why. Analysis indicates ways forward to increase applicability/usefulness, and efficiency of flow control research. Overall, greater
and more effective progress in flow control requires utilization of far more detailed information early in the research process regarding
application details and requirements.
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