A Modeling Study of Ice Accretion on a NACA 4412 Airfoil by Daniel Shields A Project Submitted to the Graduate Faculty of Rensselaer Polytechnic Institute in Partial Fulfillment of the Requirements for the degree of MASTER OF ENGINEERING IN MECHANICAL ENGINEERING Approved: _________________________________________ Ernesto Gutierrez-Miravete, Project Adviser Rensselaer Polytechnic Institute Hartford, Connecticut April 2011 i © Copyright 2011 by Daniel Shields All Rights Reserved ii CONTENTS A Modeling Study of Ice Accretion on a NACA 4412 Airfoil........................................... i LIST OF TABLES ............................................................................................................. v LIST OF FIGURES .......................................................................................................... vi List of Symbols ................................................................................................................ vii Keywords .......................................................................................................................... ix ACKNOWLEDGMENT ................................................................................................... x ABSTRACT ..................................................................................................................... xi 1. Introduction.................................................................................................................. 1 1.1 1.2 1.3 Atmospheric Conditions – Cloud Formation ..................................................... 3 1.1.1 Stratiform Clouds ................................................................................... 3 1.1.2 Cumuliform Clouds................................................................................ 5 Cloud Properties ................................................................................................. 7 1.2.1 Cloud drop size distribution ................................................................... 7 1.2.2 Cloud liquid water content ..................................................................... 7 Aircraft design criteria for icing environments .................................................. 7 1.3.1 FAA guidelines for continuous maximum icing conditions .................. 7 1.3.2 FAA guidelines for intermittent maximum icing conditions ................. 8 1.4 Ice Formation ..................................................................................................... 8 1.5 Methods of protection ........................................................................................ 9 2. Methodology .............................................................................................................. 11 2.1 Water drop trajectory ....................................................................................... 11 2.1.1 Drop trajectory calculations ................................................................. 11 2.1.2 Supercooled drop heat balance............................................................. 12 2.2 Ice Accretion Parameter ................................................................................... 13 2.3 Model Development ......................................................................................... 14 3. Results........................................................................................................................ 17 iii 3.1 Ice Accretion Parameter ................................................................................... 17 3.2 LEWICE Solutions .......................................................................................... 18 4. Conclusions................................................................................................................ 21 5. References.................................................................................................................. 22 6. Appendices ................................................................................................................ 23 6.1 Appendix A – Test Data Correlation ............................................................... 24 6.2 Appendix B – Input Files and Raw Data ......................................................... 26 6.2.1 Run 1 27 6.2.2 Run 2 30 6.2.3 Run 3 33 6.2.4 Run 4 36 6.2.5 Run 5 39 6.2.6 Run 6 42 6.2.7 Run 7 45 6.2.8 Run 8 48 6.2.9 Run 9 51 6.2.10 Run 10 54 6.2.11 Run 11 57 6.2.12 Run 12 60 6.2.13 Run 13 63 6.2.14 Run 14 66 6.2.15 Run 15 69 iv LIST OF TABLES Table 1: Table of Runs .................................................................................................... 15 v LIST OF FIGURES Figure 1: Captain Pawlik is lowered to safety during the first external hoist helicopter rescue. [1] .......................................................................................................................... 1 Figure 2: Stratiform Clouds [7] ......................................................................................... 3 Figure 4: Cumuliform Clouds [7] ...................................................................................... 6 Figure 5: Cumulus cloud water distribution [10] .............................................................. 6 Figure 6: Rime ice accretion [8] ........................................................................................ 9 Figure 7: Glaze ice accretion [9] ....................................................................................... 9 Figure 8: Particle force balance x-direction [2] ............................................................... 12 Figure 9: Energy balance at airfoil surface. [3] ............................................................... 13 Figure 10: Atmospheric icing conditions – Continuous maximum (Stratiform Clouds) [10]................................................................................................................................... 15 Figure 11: Liquid water content vs. cloud horizontal distance [10] ................................ 16 Figure 12: Ice accretion parameter as a function of temperature and airspeed ............... 17 Figure 13: Ice shape predictions - 15μm MVD, 155 knots, varying temperature and LWC. ............................................................................................................................... 18 Figure 14: Comparison of ice accretion parameter and volume of ice thickness - 15μm MVD, 155 knots. ............................................................................................................. 18 Figure 15: LEWICE results - 15μm MVD, 77 knots, varying temperature and LWC. ... 19 Figure 16: Comparison of ice accretion parameter and volume of ice thickness - 15μm MVD, 155 knots .............................................................................................................. 19 Figure 17: LEWICE Results - 25μm MVD, 155 knots, varying temperature and LWC. 20 Figure 18: Comparison of ice accretion parameter and volume of ice thickness - 25μm MVD, 155 knots. ............................................................................................................. 20 vi List of Symbols Symbol Description Units Q Total Energy BTU/hr qin Heat transferred out BTU/hr qout Heat transferred in BTU/hr qc Heat transferred due to convection BTU/hr qe Heat transferred due to evaporation BTU/hr qw Heat transferred due to sensible heat BTU/hr qf Heat transferred due to heat of fusion BTU/hr qv Heat transferred due to viscous heating BTU/hr qk Heat transferred due to kinetic energy BTU/hr Aice MVD Kts LWC Ice accretion parameter dimensionless Mean drop diameter μm Airspeed kts g/m3 Liquid water content V Aircraft velocity ft/s t Time min Fx Sum of forces in the x-direction lbf Fax Sum of aerodynamic forces in the x-direction lbf Fgx Sum of gravitational forces in the x-direction lbf md Mass of supercooled drop Cd Drop coefficient of drag ρa Density of air g/m3 ρd Density of supercooled drop g/m3 Ad Drop surface area in2 D Drop diameter in Vres Resultant velocity ft/s urel x-direction velocity ft/s fc Convective heat transfer coefficient g dimensionless vii BTU/hr-ft2-°F °F t∞ Ambient temperature Le Latent heat of vaporization of water BTU/lb Psi Ambient pressure in of Hg Psw Vapor pressure over water in of Hg Rw Rate of water catch lb/hr-ft2 n Freezing fraction As Surface area dimensionless in2 r “recovery” factor applying to kinetic heating g Acceleration due to gravity J Mechanical equivalent of heat Cp Specific heat ρice Density of accreted ice dimensionless ft/s2 778ft-lbs per BTU BTU/lb-°F g/m3 c Chord length in B Absolute ambient pressure in of Hg α Angle of attack degrees viii Keywords Ice Accretion Build-up of ice on an aircraft surface. Accretion parameter Theoretical value for predicting ice severity. LEWICE Computer code for predicting ice growth on an aircraft surface. NACA 4412 Airfoil shape developed by the National Advisory Committee for Aeronautics. Stratiform Clouds Thinner atmospheric cloud sometime spanning thousands of miles. Cumuliform Clouds Severe weather cloud. ix ACKNOWLEDGMENT To my wife Dawn, thank you for your love and understanding during the pursuit of my degree. I could not have completed this without you. For Colton. x ABSTRACT This report describes result of the study designed to investigate the phenomenon of ice accretion in a standard airfoil at different conditions defined by the FAA 14CFR Part 29 Appendix C. This is an important problem in the aerospace industry because many rotorcraft accidents occur due to the formation of ice on aircraft control surfaces, fuselage, and engine inlets. The continued flight safety of a rotorcraft in all environments (all weather aircraft) is a primary goal for rotorcraft manufacturers and owners alike. In this study, the LEWICE code was used to model ice accretion on a NACA4412 airfoil subjected to an icing environment. The objective was to determine the effect of varying different atmospheric conditions on the shape and thickness of the ice. The LEWICE results are compared to a simplified ice accretion parameter based on the classical icing accretion parameter. The purpose of the accretion parameter in this application was to identify the severity of different atmospheric icing conditions using the basic atmospheric parameters governing the FAA certification testing guidelines. It will be shown that the accretion parameter is a good indicator of icing environment severity for certification; however, it has limited value in predicting ice accretion thickness at temperatures approaching the freezing point. xi 1. Introduction Helicopters have been used for military and civilian lifesaving missions since the mid 1940’s. In January 1944 a helicopter flew plasma to injured crewmen of the USS Turner after an explosion ripped through the destroyer off the coast of Sandy Hook NJ. Later that year, a helicopter rescued a boy stranded on a sandbar in Jamaica Bay, NY. About the same time in Burma, helicopters were being used in the first combat rescue missions. The first rotorcraft external hoist rescue off the coast of Fairfield, CT, in inclement weather, in November 1945, the modern rotorcraft has been the most desirable tool in conducting search and rescue operations around the globe. Aviation pioneer Igor Sikorsky was quoted as saying “If a man is in need of rescue, an airplane can come and throw flowers on him, and that’s just about all. But a direct lift aircraft could come in and save his life.”[1] Since that first rescue 65 years ago, the expanding role of the rotorcraft for search and rescue operations in new and expanding world markets expose the vehicle to extremely adverse weather conditions. Figure 1: Captain Pawlik is lowered to safety during the first external hoist helicopter rescue. [1] The certification of rotorcraft still depends on experimental wind tunnel and flight testing; however, the increasing capability of computer processing speed has allowed for 1 more detailed analysis using computational fluid dynamics (CFD) with particle tracking analysis. It is this type of computational analysis that will be discussed herein. The formation of ice on aircraft is the most critical natural hazard affecting the safe operation of aircraft and it has been a concern since the early days of aviation. Even today,, aircraft accidents continue to occur due to the formation of ice on aircraft control surfaces, fuselage, and engine inlets. The resulting ice formations on the airframe decreases lift and engine capability and increases weight, drag and stalling speed. Accretion of ice on aircraft surfaces is the result of a tendency for water drops in atmospheric clouds to stay in a liquid state even at temperatures as low as -40°C. Supercooled drops are observed when the liquid temperature gradient at the drop surface is larger than the air temperature gradient at the surface of the drop [2]. These supercooled drops will crystallize in the presence of a seed such as another ice crystal, snow flake, dust or dirt. In the absence of any seeds, the water drops can remain in the liquid phase until they come in contact with something that will promote freezing such as an aircraft surface. There are several approaches to protecting aircraft from excessive ice accretion. The first method has been employed since the 1930’s and involves allowing a small amount of ice to form on a surface and then locally deforming that surface to break the ice away. In the early days this usually involved a pneumatically inflated rubber bladder on the leading edge of the wing. With today’s technology, the method remains the same but in place of a rubber bladder, carbon fiber composites can be used along with an electrical expulsive device. The second method involves heating the surface to either prevent ice from forming or to heat the surface at specific intervals to shed ice that has formed on the surface. Several rotorcrafts are certified for operation in forecast icing conditions and while the method of protection may differ greatly, the design and development of such technologies depends upon knowledge of atmospheric conditions, icing properties, water drop kinematics, heat transfer and fluid mechanics. 2 1.1 Atmospheric Conditions – Cloud Formation Clouds develop when air cools adiabatically as it ascends and expands. The water vapor undergoes a change of state from gas to liquid as it condenses at lower temperatures and pressures. There are two types of clouds generally associated with aircraft icing: stratiform (layer type clouds) and cumuliform (vertical development cloud). 1.1.1 Stratiform Clouds Stratiform clouds (Figure 2) are a horizontal layering of clouds consisting of three separate levels with a generally uniform base. The horizontal base of these clouds can span for a thousand square miles. Icing in stratiform clouds normally occurs in the lower two levels, at altitudes below 20,000 feet. Figure 2: Stratiform Clouds [7] The lower level stratiform clouds (<6,500 feet) known as stratocumulus, stratus and nimbostratus are generally the most important to the icing environment because of the higher cloud liquid water content and the extensive cloud coverage. These lower clouds are characterized by the white to gray appearance with repetitive masses or rolls, low ragged dark clouds or uniform gray sheet like clouds resembling fog. 3 High level stratiform clouds (>20,000 feet), do not contain liquid water because water that precipitates out of solution freezes instantly forming ice crystals regardless of drop size or lack of seed crystals. Ice crystals at these conditions do not contribute to aircraft icing in any way. It should be noted that ice crystallization is an extremely important atmospheric condition for the aerospace industry but it is outside the scope of this paper and therefore will not be addressed. Cloud properties such as liquid water, drop size and temperature vary greatly in stratiform clouds as indicated by the temperature, liquid water and drop diameter plots in Figure 3. For example, lower stratiform cloud temperature in the cloud decreases with altitude while liquid water content however, will increase. The liquid water content and drop size in the low level stratiform clouds will generally reach its maximum at or near the top of the cloud due to adiabatic lifting. Adiabatic lifting predicts an increase in the liquid water as cloud temperature decreases due to the air’s decreased ability to hold water in vapor form [10]. Figure Stratiform Cloud Properties [9] Figure 3:3: Stratiform Cloud Properties [10] 4 At higher levels there is less dependence of liquid water content and drop size on temperature. The non-uniform changes between temperature and other cloud properties with altitude results in many levels of icing severity at different altitudes. Stratiform clouds can result in prolonged icing exposure and form the criteria used for design points of ice protection systems. 1.1.2 Cumuliform Clouds Cumuliform clouds (Figure 4) are clouds which form rapidly and generally in a vertical direction. Characterized by their flat bases, and vertical formation, these types of clouds are most commonly associated with severe weather such as thunderstorms, hail, and tornadoes. Cumuliform clouds can contain large amounts of liquid water and because of adiabatic lifting can result in supercooled drops. Cumuliform clouds are not as stable as stratiform clouds and because of their vertical formation have a much smaller footprint, generally about 4 to 6 square miles. The only type of cumuliform cloud that contains the proper conditions for icing is the cumulonimbus cloud. Icing conditions in these clouds can vary greatly and depend largely on the stage of development of the cloud. Figure 5 is a diagram of drop distribution in cumulus clouds. In the lower levels of the cumulus cloud, Zone I, newly formed drops begin to precipitate out of the air. As the air and drops in the cloud rises due to adiabatic lifting, more water precipitates out and coalesces, Zone II. Zone III in the center top of the cloud contains the largest drops due mainly to coalescence. The upper outer edges of the cloud, Zone IV, the drops shrink in size due to evaporation. [9] 5 Figure 4: Cumuliform Clouds [7] Figure 5: Cumulus cloud water distribution [10] 6 1.2 Cloud Properties NASA is constantly collecting atmospheric and cloud data with the intent of defining and bounding the internal structure and water distribution of atmospheric clouds. Variations in cloud properties are dependent on many things including time of the year, seasons, and geography. 1.2.1 Cloud drop size distribution The distribution of cloud water drop sizes is never uniform across the cloud. The total liquid water content of the cloud can be calculated if the concentration of drops is grouped by drop sizes. However, in most cases the entire distribution can be adequately represented by the median volume drop diameter (MVD). MVD is expressed in μm and typically ranges from 2-50μm in diameter. 1.2.2 Cloud liquid water content The liquid water content (LWC) is the most important factor in icing. LWC represents the amount of liquid water and is expressed in grams of liquid water per cubic meter of air. LWC includes water in supercooled form only. Water in vapor form is not considered until it condenses in to liquid form with decreasing temperature or pressure. LWC can range between 0.1 to 2.5 g/m3. 1.3 Aircraft design criteria for icing environments The Federal Aviation Administration (FAA) sets regulatory requirements based on atmospheric criteria which aircraft must comply with to certify any aircraft for inadvertent flight into un-forecast icing (30minute limit) and additional requirements to certify as an “all weather” aircraft to include flight into known icing conditions. 1.3.1 FAA guidelines for continuous maximum icing conditions The continuous maximum icing conditions set forth by the FAA are based on the stratiform cloud icing conditions described in Section 1.1.1. As mentioned above, the stratiform clouds can have a very large footprint in which icing may occur. The FAA uses statistical analysis of atmospheric data to determine a standard distance of 17.4 7 nautical miles. This distance should be the basis for designing any design of experiments; however, it should not be the only case. For cloud distances other than the standard distance determined by the FAA, a liquid water content scaler can be applied to simulate a larger cloud base. Applying the scaler quantity to the liquid water content parameter is intended to simulate the extended supercooled drop exposure from a larger cloud without increasing the test time. 1.3.2 FAA guidelines for intermittent maximum icing conditions The intermittent maximum icing conditions set forth by the FAA are based on the cumuliform clouds described above in Section 1.1.2. The horizontal footprint of the cumuliform cloud is much smaller than the stratiform cloud due to its inherent instability and vertical growth. As a result the standard distance for the intermittent maximum icing conditions is only 2.6 nautical miles. A similar scaler quantity for the intermittent maximum conditions can be applied to the liquid water content to simulate longer exposure times due to a larger cloud. 1.4 Ice Formation Upon contact of the supercooled drops on a surface, the drop will freeze and begin to form an ice accretion. The two major types of ice accretion considered are rime ice and glaze ice. Rime ice (Figure 6), occurring at very cold temperatures (-9°C and below), is where the water freezes almost instantaneously resulting in smaller ice accretions in the general vicinity of the impact. Rime ice is generally has a milky or white appearance due to the large amount of air trapped in the crystalline structure. The trapped air in the ice structure results in ice formations with feathered edges and lower densities. Glaze icing (Figure 7) generally occurs at warmer temperatures. Glaze ice accretions are generally clear smooth ice deposits. The supercooled drops do not freeze instantly therefore some of the water will flow along the airfoil surface forming a larger icing ridge or a double horn or mushroom shapes. Due to the variation in temperatures and 8 icing conditions is the atmosphere mixtures of glaze and rime ice are possible and actually quite common. Figure 6: Rime ice accretion [8] Figure 7: Glaze ice accretion [9] 1.5 Methods of protection Protection of airframe surfaces are briefly discussed, although protection methods are out of the scope of this paper. The detailed physics of how accreted ice adheres to an aircraft surface is not well understood. There is however, some experimental data available which helps describe the measurements of the adhesive (ice-to-surface bond) 9 and cohesive (ice-to-ice bond) properties of ice. The measurements include the shear force required to break the bond between the ice and surface [6]. The accretion is mainly governed by the heat transfer, which includes kinetic heating, convective cooling, evaporative cooling, and latent heat of freezing, from the aircraft surface, the supercooled water drops and the surrounding environment. One typical method of protection is quite simply heating the surface to maintain the surface above the freezing point. Heating a critical surface allows no ice to accrete locally. However, once the impinging water drops migrate to a location that is not heated, the water would freeze. By design, unheated regions of the aircraft structure do not affect the continued airworthiness of the aircraft. A different approach is to allow the ice to accrete to some small amount and only heat the surface over a short time span. The heat addition would be just enough to melt the water on a microscopic level breaking the ice’s adhesive bond with the aircraft structure. Lastly, allow ice to accrete over a short time span on a surface that would deform such that the adhesive bond between the airframe surface and the cohesive bond of the ice structure would fracture. Older technologies have been around since the early days of aviation involve using elastomeric air filled bladders and electromotive leading edge structures to break the ice from the airframe. Modern technologies involve light weight composite structures with electro-expulsive devices to locally shock the composite and break the ice bonds or actuated control surfaces to break the surface bond. There are advantages and disadvantages to each approach, power management, material selection and component criticality to name a few, and require system engineered solutions to achieve a certifiable aircraft. 10 2. Methodology 2.1 Water drop trajectory Supercooled drop trajectory calculations are used to determine where and how much ice will accrete on a surface. The volume of water that impacts the aircraft surface and freezes is a function of the water catch efficiency, the liquid water content of the cloud, the diameter of the drops, the speed of the body as it moves through the cloud, ambient pressure and temperature. These terms are some of the inputs used in ice prediction models to determine ice accretion. LEWICE, first developed in the 1980’s, uses the above parameters along with Lagrangian drop trajectory calculations to determine the path of the drops as they impact the structure. 2.1.1 Drop trajectory calculations Using a CFD flow solution the drop trajectory is calculated at the discrete node positions of the flow solution using Newtonian mechanics. The sum of the forces in the xdirection acting on the particle shown in Figure 8 is F Fax Fgx md V Fax 1 C D a Ad V 2 res cos 2 x where or 1 C D a ADVres u rel 2 with Ad D2 4 represents the aerodynamic force acting on the water drop. In addition to the aerodynamic force, the gravitational force is given by Fgx md g 1 a sin( ) d 11 where the mass of the drop is md d 4 D3 3 8 Figure 8: Particle force balance x-direction [2] The sum of forces in the y-directions would be accomplished in the same manner and are not shown in this text. 2.1.2 Supercooled drop heat balance The second part of the icing calculation involves an energy balance at the structure surface, shown in Figure 9, to determine the rate of freezing and amount of water run back. Q qin qout The energy balance at the surface includes heat lost due to convection, qc f c As 32 t evaporation P Psi qe 2.90 Le f c As sw B and sensible heat absorbed by the warming of the drop. q w Rw AC p (32 t ) Heat is added to the control surface due to the latent heat of fusion 12 q f 144nRw As viscous heating rV 2 q v f c A 2 gJc p and kinetic energy of the impinging liquid. V 2 q k Rw Ad 2 gJ The resulting energy balance accompanied with a mass balance determines the overall ice shape on the structure. [3] Figure 9: Energy balance at airfoil surface. [3] 2.2 Ice Accretion Parameter The ice accretion parameter is a non dimensional mass flux term that can be thought of as the thickness of ice that would form on a flat plate placed perpendicular to the freestream flow for a period of time. The accretion parameter is defined as Aice V LWC t ice c 13 A simplified accretion parameter using the three readily available parameters, airspeed, liquid water content, and time to describe the severity of the icing conditions shall be used herein. 2.3 Model Development The intent of this project is to model a NACA4412 airfoil which is then subjected to an icing environment to determine the effect of varying different atmospheric conditions in accordance with the FAA guidelines outlined in Appendix C of 14CFR Part 29 on the shape and thickness of the ice. The variables to be analyzed include temperature, liquid water content (LWC), median volume drop diameter (MVD) and the vehicle airspeed. Each condition will be varied independently to determine the effect on ice shape and thickness. The type of ice accretion, rime or glaze, will not be considered. Each set of independent runs will be compared to a hand calculation using the ice accretion parameter to verify the validity and severity of the run. A matrix of runs with each variable and the corresponding accretion parameter is shown in Table 1. The results of the LEWICE calculations will be a two dimensional ice shape plot which will be integrated to find the volume of ice per airfoil unit length. The trends of the results will then be compared to the ice accretion parameter. The conditions selected are values consistent with the typical rotorcraft continuous maximum icing envelope as described by 14CFR Part 29 Appendix C (Figures 10 and 11) for a total of 15 runs. The selected runs in this case will assume worst case liquid water content at that given temperature for a standard cloud distance. For example, from figure 9 the maximum liquid water content observed at -30°C (-22°F) would be 0.2g/m3 and would have a median drop diameter of 15 μm. The same -30°C point for Run 11 would only have a liquid water content of 0.1g/m3 with a median drop diameter of 25 μm. For this analysis all of the runs are completed assuming the horizontal extent of the cloud is the standard distance for the continuous maximum. The intermittent maximum values of LWC and drop size are higher and should result in higher ice accretion values; however, the continuous maximum envelope outlined in Figures 10 and 11 was used to 14 establish a trend in the thickness data that could be extrapolated to include the intermittent maximum values. Table 1: Table of Runs Run Temperature MVD (°C) LWC Time Velocity (microns) (g/m3) (min) (knots) 1 -30 15 0.2 30 155 2 -20 15 0.3 30 155 3 -10 15 0.6 30 155 4 -5 15 0.7 30 155 5 0 15 0.8 30 155 6 -30 15 0.2 30 77 7 -20 15 0.3 30 77 8 -10 15 0.6 30 77 9 -5 15 0.7 30 77 10 0 15 0.8 30 77 11 -30 25 0.1 30 155 12 -20 25 0.15 30 155 13 -10 25 0.32 30 155 14 -5 25 0.41 30 155 15 0 25 0.5 30 155 15 0.9 32deg 14deg -4deg -22deg Data Points 0.8 Liquid Water Content (g/m3) 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 10 15 20 25 30 35 Mean Effective Drop Diameter (μm) Figure 10: Atmospheric icing conditions – Continuous maximum (Stratiform Clouds) [10] 15 40 1.6 1.34 1.4 Liquid Water Content Factor 1.2 1 0.8 0.6 0.4 310 0.2 0 1 10 100 17.4 Cloud Horizontal Extent (NM) Figure 11: Liquid water content vs. cloud horizontal distance [10] 16 1000 3. Results 3.1 Ice Accretion Parameter The results of the ice accretion parameter, simulating a “worst case” flat plate accreting ice with one hundred percent catch efficiency, are shown in Figure 12 derived from the FAA guidelines outlined in 14CFR Part 29 Appendix C - Continuous Maximum Icing Conditions at Standard Distance. The ice accretion parameter, a function of liquid water content, airspeed and time show an increasing trend as temperature increases from -30°C to 0°C. This is largely due to two of the three independent variables of the accretion parameter increasing resulting in the mass fraction of water available in the atmosphere and liquid water content increasing with increasing temperature shown in the FAA guidelines (Figures 10 and 11). The ice accretion parameter however does not account for the heat flux at the airfoil surface and assumes that 100% of the water freezes instantaneously (no runback). With increasing airspeed, the mass flux, amount of water impinging on the surface of the airfoil increases. Secondary effects of the higher velocities include the increased convection heat transfer coefficient and viscous heating of the aircraft surface. 4000 15MVD 155 Kts 15MVD 77 Kts 25MVD 155 Kts 3000 3 Accretion Parameter (Kts-Min-g/m ) 3500 2500 2000 1500 1000 500 0 -30 -20 -10 0 Temperature (C) Figure 12: Ice accretion parameter as a function of temperature and airspeed 17 3.2 LEWICE Solutions The results of the LEWICE solutions, shown in Figure 13 through Figure 18, show the overlays of the ice shapes as a function of increasing temperature and liquid water content. Also shown are plots of ice thickness as a function of temperature along with the theoretical ice accretion parameter for the same conditions. Conditions 1 through 4, from matrix in Table 1, show that the formation of ice increases with increasing temperature up to approximately -5°C. Above -5°C, the amount of ice accreting decreases rapidly reaching zero at 0°C. 0.060 0.040 -1C -5.5C -10C -20C -30C y/c 0.020 0.000 -0.020 -0.040 -0.060 -0.050 0.000 0.050 0.100 0.150 0.200 x/c Figure 13: Ice shape predictions - 15μm MVD, 155 knots, varying temperature and LWC. 4000 0.06 3500 0.05 3000 0.03 2000 Ice Thickness Accretion Parameter 0.04 2500 1500 Accretion Parameter LEWICE Data 0.02 1000 0.01 500 0 0 -30 -20 -10 0 Temperature (C) Figure 14: Comparison of ice accretion parameter and volume of ice thickness 15μm MVD, 155 knots. 18 The test matrix conditions 5 through 8 repeat the points at a slower airspeed. Similar to runs 1 through 4, the volume of ice will increase with increasing temperature, although at a much lower rate due to the decreased volume of water impingement, until approximately the same temperature before decreasing to zero. 0.060 0.040 y/c 0.020 -1C -5.5C -10C -20C -30C 0.000 -0.020 -0.040 -0.060 -0.050 0.000 0.050 0.100 0.150 0.200 x/c Figure 15: LEWICE results - 15μm MVD, 77 knots, varying temperature and LWC. 2000 0.025 1800 1600 0.02 1200 0.015 1000 800 0.01 Ice Thickness (in) Accretion Parameter 1400 Accretion Parameter LEWICE Data 600 400 0.005 200 0 0 -30 -20 -10 0 Temperature (C) Figure 16: Comparison of ice accretion parameter and volume of ice thickness 15μm MVD, 155 knots 19 The final conditions from the test matrix, runs 9 through 12, repeat the same airspeed and temperatures as runs 1 through 4 with an increased drop size (25 µm). Again similar to the two other batch runs, the ice accretion increases, again at a much lower rate, up to approximately -5°C before decreasing rapidly. 0.060 0.040 -1C -5.5C -10C -20C -30C y/c 0.020 0.000 -0.020 -0.040 -0.060 -0.050 0.000 0.050 0.100 0.150 0.200 x/c Figure 17: LEWICE Results - 25μm MVD, 155 knots, varying temperature and LWC. 2500 0.045 0.04 2000 0.035 0.025 0.02 Ice Thickness Accretion Parameter 0.03 1500 1000 Accretion Parameter LEWICE Thickness Results 0.015 0.01 500 0.005 0 0 -30 -20 -10 0 Temperature (C) Figure 18: Comparison of ice accretion parameter and volume of ice thickness 25μm MVD, 155 knots. 20 4. Conclusions Overall the analytical predictions from the LEWICE software show an increasing ice accretion with increasing airspeed, and liquid water content, similar to the derived ice accretion parameter. This trend has been verified experimentally in numerous papers.[2] It should be noted that the airspeeds evaluated herein are relatively low with respect to fixed wing aircraft or the rotating blade of a rotorcraft. The scope of this paper is focused on the accretion of the airframe structure. The ice accretion parameter however assumes all drops impinging on a surface freezes (a water catch efficiency of 1) and does not account for the heat flux term at the surface of the airfoil at warmer temperatures. As a result, the accretion parameter will over predict the severity of the icing results at temperatures above -6°C. At colder temperatures, the ice accretions, rime icing, are smaller and more compact due to the instantaneous freezing from the higher heat flux of the supercooled drops. This quick freezing allows for more air to become trapped in the ice and the resulting density of ice is much lower than the warmer temperature results. Also, at colder temperatures the lower mass fraction of water in the air results in lower accretion values. Warmer temperatures and lower heat flux values result in a slower freezing rate and less air being trapped in the ice formations. 21 5. References [1] Sikorsky Archives, n.d, http://www.sikorskyarchives.com/first.html November 2010 [2] Gent, R.W., Dart, N.P., Cansdale, J.T., “Aircraft Icing,” Philosophical Transactions: Mathematical, Physical and Engineering Sciences, Vol. 358, No. 1776, November 2000, pp. 2873-2911. [3] Messinger, B.L., “Equilibrium Temperature of an Unheated Icing Surface as a Function of Air Speed,” Journal of The Aeronautical Sciences, Vol. 20, No. 1, January 1953, pp. 29-42. [4] Naterer, G.F., “Energy Balances at the Air/Liquid and Liquid/Solid Interfaces with Incoming Droplets at a Moving Ice Boundary,” International. Journal of. Heat and Mass Transfer, Vol. 29, No. 1, 2002, pp. 57-66. [5] Myers, T.G., Hammond, D.W., “Ice and Water Film Growth from Incoming Supercooled Droplets,” International Journal of Heat and Mass Transfer, Vol. 42, 1999, pp2233-2242. [6] Raraty, L.E., Tabor, D., “The Adhesion and Strength Properties of Ice,” Proceedings of the Royal Society, Vol. XXA245, No. 1241, June 1958, pp. 184-201. [7] Dutch, Steven. “Clouds.” Steven Dutch, Natural and Applied Sciences. n.d. November 2010. http://www.uwgb.edu/dutchs/EarthSC102Notes/102Clouds.htm [8] C3VP, Canadian CloudSat/CALIPSO Validation. n.d, November 2010, http://c3vp.org.field/avisa/avisa.html [9] http://www.onera.fr.omph-en/icing/index.php November 2010 [10] FAA Aircraft Icing Handbook, US Department of Transportation, Federal Aviation Administration, March 1991 22 6. Appendices 23 6.1 Appendix A – Test Data Correlation A large portion of this project was used attempting to match the analytical results from the LEWICE code to experimental icing test results further validating NASA’s code for use in future engine icing certification applications. Although some of the data points produced similar shapes, overall the results were unsuccessful. This was due to a number of limitations of the 2-dimensional representation of the geometry tested. The biggest factor was that some of the profiles selected for analysis were not a good representation of the actual 3-dimensional geometry. For some of the profiles selected, the leading edge of the duct was not perpendicular to the flow The simplification from 3D to 2D ignored the leading edge rake angle. The test results generally showed a larger less dense rime ice accretions even at warmer temperatures where glaze ice was expected. 24 Test Data vs. Lewice Predictions 1.50 1.00 Lewice Angle of Attack = 2deg y (in) 0.50 Wind Tunnel Test Data 0.00 Lewice Angle of Attack = 0deg -0.50 -1.00 -1.50 -2.00 -1.00 0.00 1.00 x (in) 25 2.00 3.00 4.00 6.2 Appendix B – Input Files and Raw Data Code for the LEWICE input files and data outputs are contained in Appendix B. The code within can be copied and pasted into an input file to recreate the results shown in Section 4. 26 6.2.1 Run 1 Run 1 – -30C, 15MVD, 0.2g/m^3, 155kts, 30min &LEW20 TSTOP = 1800. IBOD = 1 IFLO = 15 DSMN = 4.0D-4 NPL = 24 &END &DIST FLWC = 1.0 DPD = 15. &END &ICE1 CHORD = 0.9144 AOA = 0 VINF = 79.738 LWC = 0.2 TINF = 243.15 PINF = 101325.00 RH = 100.0 &END &LPRNT FPRT = 1 HPRT = 1 BPRT = 1 TPRT = 0 &END &RDATA &END &BOOT &END 27 Run 1: Ice Shape 0.040 0.030 0.020 y/c 0.010 0.000 -0.010 -0.020 -0.030 -0.040 -0.050 0.000 0.050 0.100 x/c 28 0.150 0.200 Run 1: Thickness 0.025 0.020 Thickness 0.015 0.010 0.005 0.000 -0.005 -0.100 -0.080 -0.060 -0.040 -0.020 0.000 s/c 29 0.020 0.040 0.060 0.080 0.100 6.2.2 Run 2 Run 2 -20C, 15MVD, 0.3g/m^3, 155kts &LEW20 TSTOP = 1800. IBOD = 1 IFLO = 15 DSMN = 4.0D-4 NPL = 24 &END &DIST FLWC = 1.0 DPD = 15. &END &ICE1 CHORD = 0.9144 AOA = 0 VINF = 79.738 LWC = 0.3 TINF = 253.15 PINF = 101325.00 RH = 100.0 &END &LPRNT FPRT = 1 HPRT = 1 BPRT = 1 TPRT = 0 &END &RDATA &END &BOOT &END 30 Run 2: Ice Shape 0.040 0.030 0.020 y/c 0.010 0.000 -0.010 -0.020 -0.030 -0.040 -0.050 0.000 0.050 0.100 x/c 31 0.150 0.200 Run 2: Thickness 0.030 0.025 Thickness 0.020 0.015 0.010 0.005 0.000 -0.005 -0.100 -0.080 -0.060 -0.040 -0.020 0.000 s/c 32 0.020 0.040 0.060 0.080 0.100 6.2.3 Run 3 Run 3 - -20C, 15MVD, 0.6g/m^3, 155kts, 30min &LEW20 TSTOP = 1800. IBOD = 1 IFLO = 15 DSMN = 4.0D-4 NPL = 24 &END &DIST FLWC = 1.0 DPD = 15. &END &ICE1 CHORD = 0.9144 AOA = 0 VINF = 79.738 LWC = 0.6 TINF = 263.15 PINF = 101325.00 RH = 100.0 &END &LPRNT FPRT = 1 HPRT = 1 BPRT = 1 TPRT = 0 &END &RDATA &END &BOOT &END 33 Run 3: Ice Shape 0.040 0.030 0.020 y/c 0.010 0.000 -0.010 -0.020 -0.030 -0.040 -0.050 0.000 0.050 0.100 x/c 34 0.150 0.200 Run 3: Thickness 0.060 0.050 Thickness 0.040 0.030 0.020 0.010 0.000 -0.010 -0.100 -0.080 -0.060 -0.040 -0.020 0.000 s/c 35 0.020 0.040 0.060 0.080 0.100 6.2.4 Run 4 Run 3.5 - -5.5C, 15MVD, 0.7g/m^3, 155kts &LEW20 TSTOP = 1800. IBOD = 1 IFLO = 15 DSMN = 4.0D-4 NPL = 24 &END &DIST FLWC = 1.0 DPD = 15. &END &ICE1 CHORD = 0.9144 AOA = 0 VINF = 79.738 LWC = 0.7 TINF = 267.65 PINF = 101325.00 RH = 100.0 &END &LPRNT FPRT = 1 HPRT = 1 BPRT = 1 TPRT = 0 &END &RDATA &END &BOOT &END 36 Run 4: Ice Shape 0.060 0.040 y/c 0.020 0.000 -0.020 -0.040 -0.060 -0.050 0.000 0.050 0.100 x/c 37 0.150 0.200 Run 4: Thickness 0.060 0.050 Thickness 0.040 0.030 0.020 0.010 0.000 -0.010 -0.100 -0.080 -0.060 -0.040 -0.020 0.000 s/c 38 0.020 0.040 0.060 0.080 0.100 6.2.5 Run 5 Run 4 &LEW20 TSTOP = 1800. IBOD = 1 IFLO = 15 DSMN = 4.0D-4 NPL = 24 &END &DIST FLWC = 1.0 DPD = 15. &END &ICE1 CHORD = 0.9144 AOA = 0 VINF = 79.738 LWC = 0.8 TINF = 272.15 PINF = 101325.00 RH = 100.0 &END &LPRNT FPRT = 1 HPRT = 1 BPRT = 1 TPRT = 0 &END &RDATA &END &BOOT &END 39 Run 5: Ice Shape 0.040 0.030 0.020 y/c 0.010 0.000 -0.010 -0.020 -0.030 -0.040 -0.050 0.000 0.050 0.100 x/c 40 0.150 0.200 Run 5: Thickness 1.000 0.900 0.800 0.700 No accretion present for Thickness 0.600 0.500 this temperature 0.400 0.300 0.200 0.100 0.000 -0.100 -0.080 -0.060 -0.040 -0.020 0.000 s/c 41 0.020 0.040 0.060 0.080 0.100 6.2.6 Run 6 Run 5 &LEW20 TSTOP = 1800. IBOD = 1 IFLO = 15 DSMN = 4.0D-4 NPL = 24 &END &DIST FLWC = 1.0 DPD = 15. &END &ICE1 CHORD = 0.9144 AOA = 0 VINF = 39.612 LWC = 0.2 TINF = 243.15 PINF = 101325.00 RH = 100.0 &END &LPRNT FPRT = 1 HPRT = 1 BPRT = 1 TPRT = 0 &END &RDATA &END &BOOT &END 42 Run 6: Ice Shape 0.040 0.030 0.020 y/c 0.010 0.000 -0.010 -0.020 -0.030 -0.040 -0.050 0.000 0.050 0.100 x/c 43 0.150 0.200 Run 6: Thickness 0.009 0.008 0.007 0.006 Thickness 0.005 0.004 0.003 0.002 0.001 0.000 -0.001 -0.100 -0.080 -0.060 -0.040 -0.020 0.000 s/c 44 0.020 0.040 0.060 0.080 0.100 6.2.7 Run 7 Run 6 &LEW20 TSTOP = 1800. IBOD = 1 IFLO = 15 DSMN = 4.0D-4 NPL = 24 &END &DIST FLWC = 1.0 DPD = 15. &END &ICE1 CHORD = 0.9144 AOA = 0 VINF = 39.612 LWC = 0.3 TINF = 253.15 PINF = 101325.00 RH = 100.0 &END &LPRNT FPRT = 1 HPRT = 1 BPRT = 1 TPRT = 0 &END &RDATA &END &BOOT &END 45 Run 7: Ice Shape 0.040 0.030 0.020 y/c 0.010 0.000 -0.010 -0.020 -0.030 -0.040 -0.050 0.000 0.050 0.100 x/c 46 0.150 0.200 Run 7: Thickness 0.014 0.012 0.010 Thickness 0.008 0.006 0.004 0.002 0.000 -0.002 -0.100 -0.080 -0.060 -0.040 -0.020 0.000 s/c 47 0.020 0.040 0.060 0.080 0.100 6.2.8 Run 8 Run 7 &LEW20 TSTOP = 1800. IBOD = 1 IFLO = 15 DSMN = 4.0D-4 NPL = 24 &END &DIST FLWC = 1.0 DPD = 15. &END &ICE1 CHORD = 0.9144 AOA = 0 VINF = 39.612 LWC = 0.6 TINF = 263.15 PINF = 101325.00 RH = 100.0 &END &LPRNT FPRT = 1 HPRT = 1 BPRT = 1 TPRT = 0 &END &RDATA &END &BOOT &END 48 Run 8: Ice Shape 0.040 0.030 0.020 y/c 0.010 0.000 -0.010 -0.020 -0.030 -0.040 -0.050 0.000 0.050 0.100 x/c 49 0.150 0.200 Run 8: Thickness 0.025 0.020 Thickness 0.015 0.010 0.005 0.000 -0.005 -0.100 -0.080 -0.060 -0.040 -0.020 0.000 s/c 50 0.020 0.040 0.060 0.080 0.100 6.2.9 Run 9 Run 8.5 &LEW20 TSTOP = 1800. IBOD = 1 IFLO = 15 DSMN = 4.0D-4 NPL = 24 &END &DIST FLWC = 1.0 DPD = 15. &END &ICE1 CHORD = 0.9144 AOA = 0 VINF = 39.612 LWC = 0.8 TINF = 267.65 PINF = 101325.00 RH = 100.0 &END &LPRNT FPRT = 1 HPRT = 1 BPRT = 1 TPRT = 0 &END &RDATA &END &BOOT &END 51 Run 9: Ice Shape 0.040 0.030 0.020 y/c 0.010 0.000 -0.010 -0.020 -0.030 -0.040 -0.050 0.000 0.050 0.100 x/c 52 0.150 0.200 Run 9: Thickness 0.025 0.020 Thickness 0.015 0.010 0.005 0.000 -0.005 -0.100 -0.080 -0.060 -0.040 -0.020 0.000 s/c 53 0.020 0.040 0.060 0.080 0.100 6.2.10 Run 10 Run 8 &LEW20 TSTOP = 1800. IBOD = 1 IFLO = 15 DSMN = 4.0D-4 NPL = 24 &END &DIST FLWC = 1.0 DPD = 15. &END &ICE1 CHORD = 0.9144 AOA = 0 VINF = 39.612 LWC = 0.8 TINF = 272.15 PINF = 101325.00 RH = 100.0 &END &LPRNT FPRT = 1 HPRT = 1 BPRT = 1 TPRT = 0 &END &RDATA &END &BOOT &END 54 Run 10: Ice Shape 0.040 0.030 0.020 y/c 0.010 0.000 -0.010 -0.020 -0.030 -0.040 -0.050 0.000 0.050 0.100 x/c 55 0.150 0.200 Run 10: Thickness 0.0045 0.0040 0.0035 0.0030 Thickness 0.0025 0.0020 0.0015 0.0010 0.0005 0.0000 -0.0005 -0.100 -0.080 -0.060 -0.040 -0.020 0.000 s/c 56 0.020 0.040 0.060 0.080 0.100 6.2.11 Run 11 Run 9 &LEW20 TSTOP = 1800. IBOD = 1 IFLO = 15 DSMN = 4.0D-4 NPL = 24 &END &DIST FLWC = 1.0 DPD = 25. &END &ICE1 CHORD = 0.9144 AOA = 0 VINF = 79.738 LWC = 0.1 TINF = 243.15 PINF = 101325.00 RH = 100.0 &END &LPRNT FPRT = 1 HPRT = 1 BPRT = 1 TPRT = 0 &END &RDATA &END &BOOT &END 57 Run 11: Ice Shape 0.040 0.030 0.020 y/c 0.010 0.000 -0.010 -0.020 -0.030 -0.040 -0.050 0.000 0.050 0.100 x/c 58 0.150 0.200 Run 11: Thickness 0.014 0.012 0.010 Thickness 0.008 0.006 0.004 0.002 0.000 -0.002 -0.100 -0.080 -0.060 -0.040 -0.020 0.000 s/c 59 0.020 0.040 0.060 0.080 0.100 6.2.12 Run 12 Run 10 &LEW20 TSTOP = 1800. IBOD = 1 IFLO = 15 DSMN = 4.0D-4 NPL = 24 &END &DIST FLWC = 1.0 DPD = 25. &END &ICE1 CHORD = 0.9144 AOA = 0 VINF = 79.738 LWC = 0.15 TINF = 253.15 PINF = 101325.00 RH = 100.0 &END &LPRNT FPRT = 1 HPRT = 1 BPRT = 1 TPRT = 0 &END &RDATA &END &BOOT &END 60 Run 12: Ice Shape 0.040 0.030 0.020 y/c 0.010 0.000 -0.010 -0.020 -0.030 -0.040 -0.050 0.000 0.050 0.100 x/c 61 0.150 0.200 Run 12: Thickness 0.016 0.014 0.012 Thickness 0.010 0.008 0.006 0.004 0.002 0.000 -0.002 -0.100 -0.080 -0.060 -0.040 -0.020 0.000 s/c 62 0.020 0.040 0.060 0.080 0.100 6.2.13 Run 13 Run 11 &LEW20 TSTOP = 1800. IBOD = 1 IFLO = 15 DSMN = 4.0D-4 NPL = 24 &END &DIST FLWC = 1.0 DPD = 25. &END &ICE1 CHORD = 0.9144 AOA = 0 VINF = 79.738 LWC = 0.32 TINF = 263.15 PINF = 101325.00 RH = 100.0 &END &LPRNT FPRT = 1 HPRT = 1 BPRT = 1 TPRT = 0 &END &RDATA &END &BOOT &END 63 Run 13: Ice Shape 0.040 0.030 0.020 y/c 0.010 0.000 -0.010 -0.020 -0.030 -0.040 -0.050 0.000 0.050 0.100 x/c 64 0.150 0.200 Run 13: Thickness 0.035 0.030 0.025 Thickness 0.020 0.015 0.010 0.005 0.000 -0.005 -0.100 -0.080 -0.060 -0.040 -0.020 0.000 s/c 65 0.020 0.040 0.060 0.080 0.100 6.2.14 Run 14 Run 11.5 &LEW20 TSTOP = 1800. IBOD = 1 IFLO = 15 DSMN = 4.0D-4 NPL = 24 &END &DIST FLWC = 1.0 DPD = 25. &END &ICE1 CHORD = 0.9144 AOA = 0 VINF = 79.738 LWC = 0.32 TINF = 267.65 PINF = 101325.00 RH = 100.0 &END &LPRNT FPRT = 1 HPRT = 1 BPRT = 1 TPRT = 0 &END &RDATA &END &BOOT &END 66 Run 14: Ice Shape 0.040 0.030 0.020 y/c 0.010 0.000 -0.010 -0.020 -0.030 -0.040 -0.050 0.000 0.050 0.100 x/c 67 0.150 0.200 Run 14: Thickness 0.045 0.040 0.035 0.030 Thickness 0.025 0.020 0.015 0.010 0.005 0.000 -0.005 -0.100 -0.080 -0.060 -0.040 -0.020 0.000 s/c 68 0.020 0.040 0.060 0.080 0.100 6.2.15 Run 15 Run 12 &LEW20 TSTOP = 1800. IBOD = 1 IFLO = 15 DSMN = 4.0D-4 NPL = 24 &END &DIST FLWC = 1.0 DPD = 25. &END &ICE1 CHORD = 0.9144 AOA = 0 VINF = 79.738 LWC = 0.5 TINF = 272.15 PINF = 101325.00 RH = 100.0 &END &LPRNT FPRT = 1 HPRT = 1 BPRT = 1 TPRT = 0 &END &RDATA &END &BOOT &END 69 Run 15: Ice Shape 0.040 0.030 0.020 y/c 0.010 0.000 -0.010 -0.020 -0.030 -0.040 -0.050 0.000 0.050 0.100 x/c 70 0.150 0.200 Run 15: Thickness 1.000 0.900 0.800 0.700 No accretion present for Thickness 0.600 0.500 this temperature 0.400 0.300 0.200 0.100 0.000 -0.100 -0.080 -0.060 -0.040 -0.020 0.000 s/c 71 0.020 0.040 0.060 0.080 0.100