Laminar Flow Control Research Articles

Development of Porous Ti64 by Partial Densification in Spark Plasma Sintering for Laminar Flow Control

Development of Porous Ti64 by Partial Densification in Spark Plasma Sintering for Laminar Flow Control

Two-dimensional boundary layer receptivity to finite periodic disturbances

Receptivity is the focus and frontier of the research on boundary layer transition and flow drag reduction, but the temporal and spatial evolution of Tollmien–Schlichting waves (T-S waves) is not yet fully investigated, limiting the development of highly efficient laminar flow control techniques. In the present study, the local receptivity problem of the laminar boundary layer on a zero-pressure-gradient flat plate is investigated by using the direct numerical simulation, considering both the temporal and spatial evolution characteristics of the T-S waves. External disturbances at fixed frequencies are introduced in the form of velocity pulsations with different periods to excite T-S waves. The temporal and spatial evolution characteristics of the T-S waves excited by different forms and periods of disturbances are studied. It is found that the amplitude, frequency, and wave velocity of the T-S wave induced by the external multi-period disturbances are different from those induced by the constant disturbances. These conclusions are the same as those of T-S wave induced by wall inhalation. After a further investigation on this particular phenomenon, the influence mechanism of external disturbances on the receptivity process is revealed. This new research finding enriches the instability theory and provides a reference for more efficient applications on active laminar flow control technologies.

Energy Absorption Properties of 3D-Printed Polymeric Gyroid Structures for an Aircraft Wing Leading Edge

Laminar flow offers significant potential for increasing the energy efficiency of future transport aircraft. At the Cluster of Excellence SE2A—Sustainable and Energy-Efficient Aviation—the laminarization of the wing by means of hybrid laminar flow control (HLFC) is being investigated. The aim is to maintain the boundary layer as laminar for up to 80% of the chord length of the wing. This is achieved by active suction on the leading edge and the rear part of the wing. The suction panels are constructed with a thin micro-perforated skin and a supporting open-cellular core structure. The mechanical requirements for this kind of sandwich structure vary depending on its position of usage. The suction panel on the leading edge must be able to sustain bird strikes, while the suction panel on the rear part must sustain bending loads from the deformation of the wing. The objective of this study was to investigate the energy absorption properties of a triply periodic minimal surface (TPMS) structure that can be used as a bird strike-resistant core in the wing leading edge. To this end, cubic-sheet-based gyroid specimens of different polymeric materials and different geometric dimensions were manufactured using additive manufacturing processes. The specimens were then tested under quasi-static compression and dynamic crushing loading until failure. It was found that the mechanical behavior was dependent on the material, the unit cell size, the relative density, and the loading rate. In general, the weight-specific energy absorption (SEA) at 50% compaction increased with increasing relative density. Polyurethane specimens exhibited an increase in SEA with increasing loading rate, as opposed to the specimens of the other investigated polymers. A smaller unit cell size induced a more consistent energy absorption, due to the higher plateau force.

Streamwise-Elongated Sinusoidal Roughness Elements with Enhanced Laminarizing Effect on Three-Dimensional Boundary Layer

As a laminar flow control device for delaying the crossflow-induced transition of a three-dimensional boundary layer, sinusoidal roughness elements (SREs) are placed in a Falkner–Skan–Cooke boundary layer, and the resultant laminarizing effect is numerically investigated in comparison with discrete roughness elements (DREs). Because SREs are elongated in the streamwise direction and designed to avoid flow tripping, the critical height of SREs is much higher than that of DREs. Moreover, the wake flow behind SREs efficiently generates and sustains crossflow vortices that are not dangerously unstable against secondary instabilities but able to strongly distort the mean crossflow profile into a less unstable one. By measuring this mean flow distortion by SREs and DREs, the laminarizing effect is compared among them. It is shown that the effect of SREs is higher than that of DREs and can be enhanced by choosing the appropriate height, angle, and wavelength depending on the local boundary-layer profile.

Investigation of Hybrid Laminar Flow Control Capabilities from the Flight Envelope Perspective

The present work conducts a multifidelity aerodynamic design of a medium-range commercial aircraft wing featuring hybrid laminar flow control (HLFC) technology. The design was performed to investigate the capabilities of the HLFC, considering the entire design flight envelope, low-speed performance requirements, and various potential mission scenarios. A combination of medium-fidelity aerodynamic design tools for laminar flow control using MSES-COCO-LILO, CFD RANS for high-lift cases, the quasi-three-dimensional for database generations, and SUAVE for mission analysis were used to design and assess aircraft’s performance with the HLFC wing. Studies of the design objective demonstrated a conflict between friction and compressibility drag that strongly affects the design objective function and the wing performance at various off-design conditions. A strong dependence of HLFC on flight conditions was observed to indicate technology performance limitations and a tradeoff between airplane emissions, range, and costs. Finally, a comparison of medium- and low-fidelity performance results showed deviations in the design fuel burn of 4%, a minimum possible harmonic range difference of 3%, and direct operating costs of 2%. The outcome suggests the need for better compressibility and parasite drag models for early design stages to accurately model the HLFC technology without introducing complicated methods at the first sizing steps.

Aircraft Wing Design for Extended Hybrid Laminar Flow Control

Laminar flow offers significant potential for increasing the energy-efficiency of future transport aircraft. The German Cluster of Excellence SE2A is developing a new approach for hybrid laminar flow control. The concept aims to maintain laminar flow up to 80% of the chord length by integrating suction panels at the rear part of the wing, which consist of a thin suction skin and a supporting core structure. This study examines effects of various suction panel configurations on wing mass and load transfer for an all-electric short-range aircraft. Suction panel material, as well as thickness and relative density of the suction panel core are modified in meaningful boundaries. Suction panels made from Ti6Al4V offer the most robust design resulting in a significant increase in wing mass. For the studied configurations, they represent up to 33.8% of the mass of the wingbox. In contrast, panels made from Nylon11CF or PU1000 do not significantly increase the wing mass. However, the use of these materials raises questions about their robustness under operational conditions. The results demonstrate that the choice of material strongly influences the load path within the wing structure. Ti6Al4V suction panels provide sufficient mechanical properties to significantly contribute to load transfer and buckling stiffness. Locally, the share of load transfer attributed to the suction panel exceeds 50%. In contrast, compliant materials such as Nylon11CF or PU1000 are inherently decoupled from load transfer. Unlike the thickness of the suction skin, the relative density of the core structure strongly affects the wrinkling stiffness. However, wrinkling failure did not appear critical for the examined suction panel configurations. In the present study, the mechanical properties of Ti6Al4V cannot fully be exploited. Therefore, compliant suction panels made from Nylon11CF are preferred in order to achieve a lightweight solution, provided that they meet operational requirements.

Receptivity and Stability Theory Analysis of a Transonic Swept Wing Experiment

Surface suction provides an efficient way to delay boundary layer transitions. In order to verify the suction effects and determine the mechanism of suction control in transonic swept wing boundary layers, wind tunnel transition measurements in a hybrid laminar flow control (HLFC) wind tunnel model uses an infrared thermography technique in the Aircraft Research Association (ARA) 2.74 m × 2.44 m low turbulence level transonic wind tunnel. Based on the experimental data of stationary crossflow dominant transitions without and with surface suction in transonic swept wing boundary layers, in this paper, the effects on the receptivity and linear and nonlinear evolution of stationary crossflow vortices have been analyzed with the consideration of curvature. Theoretical analysis agreed with the experimental observations in regard to the transition delay caused by boundary layer suction near the leading-edge region.

Design of Hybrid-Laminar-Flow-Control Wing and Suction System for Transonic Midrange Aircraft

Hybrid laminar flow control (HLFC) has shown significant promise in the viscous drag reduction of aircraft. However, the use of HLFC for commercial applications requires further simplification. The current study proposes tools for the conceptual design of transonic HLFC wing and suction system. In the first part of the study, airfoil sections for the wing are optimized for minimum total drag using a multi-objective genetic algorithm approach at six spanwise locations. The induced drag of the wing is estimated using a vortex lattice method solver. In the second part of the study, suction system design is performed using ASPeCT, an in-house solver for HLFC system design. A simplified inner structure for the suction system is proposed, which can be integrated easily within the wing structure. A total drag penalty approach is proposed to establish a tradeoff between matching the target suction distribution and the complexity of the suction system. Finally, the additional weight and off-design performance of the suction system are analyzed for a ±0.1 change in the design lift coefficient. A maximum fuel reduction of 7% can be expected with the HLFC system taking into account the additional weight added and power off-take from the engine.

Aerodynamic drag reduction through a hybrid laminar flow control and variable camber coupled wing

This paper presents computational fluid dynamics (CFD) results of a transonic transport aircraft wing, featuring a hybrid laminar flow control (HLFC) and variable camber (VC) technology coupling. The goal of the paper is a quantitative assessment of synergistic effects for aerodynamic drag reduction, when combining the possibility of actively shaping the surface pressure distribution of the wing through VC with the passive natural laminar flow aspect of HLFC. Modeling approaches for both VC integration, achieved through deflections of an Adaptive Dropped Hinge Flap (ADHF), and boundary layer suction into a CFD workflow are presented. Transition prediction is accomplished with the γ−Reθ+Cross-flow(CF) transition turbulence model, and linear stability theory (LST) coupled to a two-N-factor transition prediction method. Both methods reflect synergy-driven effects. While the extent of laminar flow predicted by the γ−Reθ+CF model is limited, both favorable ADHF settings and boundary layer suction lead to an overall drag reduction. This is correspondingly reflected through the analyses via LST. Furthermore, the latter predicts a pronounced downstream shift in transition position with increasing suction strength, where the inherent differentiation of transition mechanisms in the two-N-factor method between Tollmien-Schlichting (TSI) and cross-flow instabilities (CFI) reflects a marked reduction in TSI N-factors with increasing ADHF deflection angles. Even though N-factors associated to CFI partially increase through ADHF deflections, the intended synergistic effects are represented throughout the investigated parameter range, leading to an increase in the extent of laminar flow for adequate ADHF deflection angles.

Multidisciplinary Design Optimization of Transonic Wings with Boundary-Layer Suction

A quasi-three-dimensional aerodynamic solver is developed for the aerodynamic analysis of wings in a transonic regime that is able to capture the effect of BLS in hybrid laminar flow control (HLFC) application or transition to turbulent flow for natural laminar flow (NLF). The tool provides accurate results, but without the high computational cost of high-fidelity tools. The solver combines the use of an Euler flow solver characterized by an integral boundary-layer method and linear stability analysis using a approximation for transition prediction. In particular, a conical transformation is adopted, including the determination of the shock-wave position. The solver is implemented in a multidisciplinary design optimization (MDO) framework, including wing weight estimation and aircraft performance analysis. The framework consists of different modules: aerodynamics, structure, suction system analysis, and performance evaluation. Using a genetic algorithm and considering HLFC technology, wing MDO has been performed to find the optimum wing planform and airfoil shape. A backward-swept wing (BSW) aircraft, developed inside the Cluster of Excellence–Sustainable and Energy Efficient Aviation (A) is studied. Novel technologies such as active flow control, limited maximum load factors due to load alleviation, and novel materials allow a fuel weight reduction of 6%.

Effect of local wall temperature on hypersonic boundary layer stability and transition

Wall temperature significantly affects stability and receptivity of the boundary layer. Changing the wall temperature locally may therefore be an effective laminar flow control technique. However, the situation is complicated when the wall temperature distribution is nonuniform, and researchers have experimentally found that local wall cooling may delay the onset of transition. We attempt to clarify the physical mechanisms whereby the local wall temperature affects the transition and the stability of a hypersonic boundary layer. A numerical investigation of the disturbance evolution in a Mach-6 sharp cone boundary layer with local wall heating or cooling is conducted. Direct numerical simulation (DNS) is performed for the single-frequency and broadband disturbance evolution caused by random forcing. We vary the local wall temperature and the location of heating/cooling, and then use the e N method to estimate the transition onset. Our results show that local wall cooling amplifies high-frequency unstable waves while stabilizing low-frequency unstable waves, with local heating amplifying all unstable waves locally. The disturbance amplitude and second-mode peak frequency obtained by DNS agree well with the previous experimental results. Local cooling/heating has a dual effect on the stability of the hypersonic boundary layer. For local cooling, while it effectively inhibits the growth of the low-frequency unstable waves that dominate the transition downstream, it also further destabilizes the downstream flow. In addition, while upstream cooling can delay the transition, excessive cooling may promote it; local heating always slightly promotes the transition. Finally, recommendations are given for practical engineering applications based on the present results.

Experimental and numerical investigation of different wing profiles

Computational Fluid Dynamics (CFD) techniques are widely used in product development processes due to efficient algorithms to solve Navier Stokes equations. In this study, the coordinates of the NACA 1412 and NACA 2415 sections selected from the standard wing sections of the National Aviation Advisory Committee (NACA) have been implemented with specific procedures to create new geometries and a new wing profile design using the coordinate method. The wing profile geometry is created from the coordinates available in the literature. Fixed two-dimensional viscous flows around the generated wing profiles are simulated using commercially available ANSYS-Fluent software. The mesh structure used was created using the C type and rectangular structure. CFD and wind tunnel analysis of attack angles ranging from certain degrees. The aerodynamic coefficients of the related statuses, i.e. the lift and drag coefficients obtained from the analysis, have been compared with the wind tunnel test results. Aerodynamic research in recent years focuses on active flow control concepts, laminar flow control, fuel economy and higher transport/drag force ratio. This is designed to understand and analyze flow behavior around airfoils using the CFD method.

Validation of Suction Velocity Analysis for Active Laminar Flow Control with Uncertainties

This study provides a validation of a recently developed uncertainty quantification methodology for suction velocities with the example of a novel laminar flow control design referred to as a tailored skin single duct (TSSD) panel. The TSSD panel is located on the leading edge of a vertical fin model of an Airbus A320 that is designed to maintain and extend laminar flow over the fin by means of boundary-layer suction. The suction velocities are highly dependent on the local porosity, which is only partly known in practice; therefore, the associated uncertainties need to be quantified. This is achieved by combining experimental and numerical data. The experimental data are based on the wind-tunnel experiments on a full-scale Airbus A320 vertical fin equipped with the TSSD system performed in the large low-speed facility of the German–Dutch Wind Tunnels. The measurements also feature highly accurate mass flow measurements of the integral mass flow through the TSSD system that serve as a validation reference for the uncertainty analysis. Uncertainties are provided for the predicted and the measured total mass flows to validate the proposed method, and a good agreement is obtained. A sensitivity study reveals the most influential contributions to the variance of the computed suction velocities. Depending on the difference between plenum and outer pressure, either uncertainties in the pressure distribution or uncertainties in the porosity parameters dominate the variance of the suction velocity.

Development of a medium/long-haul reference aircraft

For the evaluation of future aircraft architectures or novel technologies, a well-understood and sound reference to compare to is essential to prove the impact of intended changes. A reference aircraft serves as a basis for calibration of the aircraft and is used as a starting point for subsequent investigations, sensitivity studies or optimizations. The prime need for such a reference arose from the European Clean-Sky-2 project HLFC-Win (Hybrid Laminar Flow Control—Wing), where no industrial reference data for a conventional aircraft were available. The project investigates a HLFC system integrated into the wing aiming to reduce the wing drag and consequently reducing the fuel consumption. Therefore, this paper presents the D300-XRF1 designed by DLR, which is based on the AIRBUS research aircraft XRF1 (eXternal Research Forum). It is intended to be used as a reference aircraft database representing aircraft for medium- and long-range missions. A variable fidelity multidisciplinary design analysis and optimization (MDAO) aircraft design environment is set up to provide a consistent estimate of the geometry, mass breakdown, propulsion system, aerodynamics and aircraft performance. A conceptual aircraft design tool is utilized in the aircraft design environment to initialize the process, and higher-fidelity modules are used to enhance the results. The presented results describe the overall aircraft characteristics of the D300-XRF1 based on 2010 entry into service technology level and is offered to be used as a reference within the aviation research community, hopefully reducing similar design efforts in other research projects.The aircraft operates at a design cruise Mach number of 0.83, has a design range of 5500 NM and transports a payload of 31.5 t (300 PAX at 105 kg/PAX). The D300-XRF1 serves as a consistent reference aircraft database and provides a holistic overview of the aircraft’s performance that has been presented to and approved by AIRBUS. Therefore, this reference aircraft design can be used for future studies and to assess new technologies on a sophisticated level.

Hybrid Laminar Flow Control Optimizations for Infinite Swept Wings

Maintaining the laminar flow on surfaces through active control is a significantly promising technique for reducing fuel burn and alleviating environmental concerns in commercial aviation. However, there is a lack of systematic parameter studies for the hybrid laminar flow control (HLFC) together with natural laminar flow (NLF). To address this need, we optimize the infinite swept wings with different sweep angles and at various conditions, including different Mach numbers, Reynolds numbers, and lift coefficients. The Reynolds-averaged Navier-Stokes (RANS) solver coupled with the linear stability theory is applied for the laminar-turbulent transition prediction, and the traditional optimization method based on evolutionary algorithms is applied for laminar flow wing optimization. The optimization results found that HLFC is required when the NLF fails at a larger sweep angle (35°) and Reynolds number ( 20 × 10 6 ). The lower pressure peak with boundary-layer suction is found to delay the transition of the regional aviation condition. Besides, the pressure distribution of HLFC is similar to NLF results at the lower Reynolds number ( 10 × 10 6 ) or sweep angle (25°), i.e., a gentle negative pressure gradient near the leading edge and a small favorable pressure gradient behind it. Clarifying the characteristics of laminar flow wings will advance the application of the laminar flow technique within its field.

평균 센싱 속도를 이용한 Re=300의 반구 주위 층류 유동의 비례 되먹임 제어

본 연구에서는 시간 평균된 센싱 속도를 활용한 비례 제어 기법을 반구 주위 층류 유동에 적용하였다. 제어 입력으로서 분사/흡입 가진은 유동 박리 전 반구 표면의 국소적인 슬롯에서 일어나며, 가진의 강도는 후류 중심선에 위치한 횡방향 시간 평균 속도에 선형적으로 비례한다. 이를 위해 Re=300의 반구 주위 유동에 대한 수치해석을 수행하였다. 파라미터 연구를 통해 반구의 양력 섭동 감소를 위한 최적의 비례 게인 값을 찾아내었다. 본 연구의 비례 제어를 통해 센싱 위치의 속도 섭동을 감소시키고 후류의 와류 구조를 약화시켰으며, 이를 통해 반구가 받는 양력 섭동을 성공적으로 감소시킬 수 있음을 확인하였다.

Adjoint-based robust optimization design of laminar flow wing under flight condition uncertainties

It is an inherent uncertainty problem that the application of laminar flow technology to the wing of large passenger aircraft is affected by flight conditions. In order to seek a more robust natural laminar flow control effect, it is necessary to develop an effective optimization design method. Meanwhile, attention must be given to the impact of crossflow (CF) instability brought on by the sweep angle. This paper constructs a robust optimization design framework based on discrete adjoint methods and non-intrusive polynomial chaos. Transition prediction is implemented by coupled Reynolds-Averaged Navier-Stokes (RANS) and simplified eN method, which can consider both Tollmien-Schlichting (TS) wave and crossflow vortex instability. We have performed gradient enhancement processing on the general Polynomial Chaos Expansion (PCE), which is advantageous to reduce the computational cost of single uncertainty propagation. This processing takes advantage of the gradient information obtained by solving the coupled adjoint equations considering transition. The statistical moment gradient solution used for the robust optimization design also uses the derivatives of coupled adjoint equations. The framework is applied to the robust design of a 25° swept wing with infinite span in transonic flow. The uncertainty quantification and sensitivity analysis on the baseline wing shows that the uncertainty quantification method in this paper has high accuracy, and qualitatively reveals the factors that dominate in different flow field regions. By the robust optimization design, the mean and standard deviation of the drag coefficient can be reduced by 29% and 45%, respectively, and compared with the deterministic optimization design results, there is less possibility of forming shock waves under flight condition uncertainties. Robust optimization results illustrate the trade-off between the transition delay and the wave drag reduction.

Design Exploration of Transonic Airfoils for Natural and Hybrid Laminar Flow Control Applications

Designing transonic laminar swept wing at high Reynolds numbers is challenging due to the premature flow transition from the prominent crossflow instabilities (CFIs). Hence, natural laminar flow (NLF) wings are limited to lower sweep angles. In this study, hybrid laminar flow control (HLFC) is used to extend this limit to design low-drag transonic infinite wing. A multi-objective genetic algorithm with competing drag components as objectives is used to design NLF and HLFC airfoils. Optimal design is a tradeoff between the drag reduction from skin friction drag, pressure drag, and suction drag, and does not resemble initial airfoils. Airfoil shape and suction distribution are coupled and optimized simultaneously. Euler flow solver with integral boundary-layer method is coupled with a higher-fidelity Linear Stability Analysis using 2.5D approximation for transition prediction. At wing sweep of 22.5°, Mach number of 0.78, and Reynolds number of 30 million, optimum NLF airfoil has 27% lower drag than an optimum turbulent airfoil. The optimum HLFC airfoil showed a 25% lower total drag than the NLF airfoil. A higher optimum sweep angle was observed for low-drag HLFC airfoil (20.5°) in comparison to the NLF airfoil (16.8°) and both favored an undercut on the lower surface to dampen CFI.

The Aircraft Family Concepts for an Advanced Technology Regional Aircraft

The aim of this work is to make a feasibility study of the aircraft family concepts using a combined Hybrid Laminar Flow Control - Variable Camber Wing (HLFC-VCW) for a high subsonic Advanced Technology Regional Aircraft (ATRA). The prediction of ATRA’s performance used computational fluid dynamic and empirical methods. The aircraft family concept using a combined HLFC–VCW is feasible for the ATRA aircraft family from an aerodynamic point of view.

Comparative study of hydrogen and kerosene commercial aircraft with advanced airframe and propulsion technologies for more sustainable aviation

Present work performs a comparative study of two medium-range commercial jets with future airframe and propulsion technologies powered by hydrogen and kerosene fuel to achieve a substantial reduction in overall aviation emissions. The study aims to investigate the cumulative effect of different energy networks combined with airframe efficiency gains achieved by aircraft-related technologies to suggest a better option for the potential next-generation commercial aircraft similar to the Airbus A320. Advanced airframe and engine technologies include laminar flow control, active load alleviation, new materials and structures, and ultra-high bypass ratio turbofan engines. Two aircraft with hydrogen and kerosene propulsion systems were sized to compare their performance characteristics, equivalent CO2 emission, and direct operating costs. The design was performed using a multi-fidelity approach and included the effects of future airframe technologies and the hydrogen propulsion system. The design comparison showed a significant contribution of airframe and propulsion technologies in achieving more environmentally friendly aircraft. The green hydrogen option showed a 41–63% reduction in overall emissions compared to the kerosene aircraft depending on flight conditions while the blue hydrogen variant achieved a 21–26% reduction level. A rather optimistic price scenario shall be met to enable an operational benefit of green hydrogen while the blue hydrogen variant has more potential of being economically acceptable by the market. In circumstances when operating costs drive the decision-making more than emissions, kerosene may be a more favorable option as a compromise between emission and costs, given the positive effect of airframe and propulsion technologies.