AEROMEMS II Advanced Flow Control Using MEMS Results and Lessons Learned

Dr Clyde Warsop
Presented at 5th Community Aeronautical Days 2006

Advanced Technology Centre

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Objectives

y
y it Veloc y

y Veloc
y

Velocity

ity
Velo c ity

nt Turbule
Lam inar

Transition

Separation Wake

- Control of turbulent boundary layers using active sub-boundary layer scale devices to achieve: - Drag reduction - Flow separation control

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Enablers - Microfabrication
Sandia

Integrate Sensors, Actuators, Electronics

Microelectronics = planar Microengineering = 3-d sculpting

1 Micron Features

BAE SYSTEMS

Accelerometer Gyroscope

BAE SYSTEMS

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AEROMEMS II Overview

Sub-BL Flow Separation Control (Pulsed jets)

3mm Pulsed jet, 100 - 200 m/s 5-20% duty cycle 200 m dia

Application to High Lift, Intakes, Fans compressors

Pressurised supply (30-80 kPa)

PZT cantilever actuator 50-80 m displacement 1 - 2 KHz frequency

MEMS Sensors/Actuators
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High Re Demonstrations
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Actuator Optimisation

High Re Adverse Press Grad.

Hot wire Skin friction Steady/unsteady PIV

0.6 0.5 0.4 0.3 0.2

without actuator CtR passive devise CoR jets VR4 CoR jets VR6 CtR jets VR4 CtR jets VR6

0.6 0.5 0.4

Without actuator

u/ue 1 0.9 0.8 0.7 0.6 0.5

0.6 0.5 0.4

CtR Passive devices

y/

y/

0.3 0.2 0.1 0 -0.5 -0.4 -0.3 -0.2 -0.1

0.3 0.2 0.1 0

0.4 0.3 ue/4

z/

0.1

0.2

0.3

0.4

0.5

-0.5

-0.4

-0.3

-0.2

-0.1

z/

0.1

0.2

0.3

0.6 0.5 0.4

CoR jets VRe=3.1

u/ue 1 0.9 0.8

0.6 0.5 0.4

CtR jets VRe=3.1

y/

0.3 0.2

0.6 0.5 0.4 0.3 ue/4

y/

0.1 0 0 0.2 0.4

0.7

0.3 0.2 0.1 0

0.1

u*

0.6

0.8

0 -0.5 -0.4 -0.3 -0.2 -0.1

z/

0.1

0.2

0.3

0.4

0.5

-0.5

-0.4

-0.3

-0.2

-0.1

z/

0.1

0.2

0.3

Compare pulsed jets & synthetic jets with passive devices

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High-lift and Intake Distortion Tests

Non Actuated
Sepa n ratio

TE

LE

Actuated
Wind tunnel velocity = 30 m/s and w ing incidence angle = 10.0 deg.

TE

r Sepa

0.25 0.20 0.15 0.10 0.05 0.00 0.0 1.0 2.0 3.0 4.0 5.0
10mm spacing

Change in Lift coefficient

ation

LE

Unactuated Actuated MThroat =0.6 DC60 reduced by 40% for 0.05% engine mass flow bleed
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Velocity ratio

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Compressor surge tests

1.018 1.017 1.016 1.015 1.014 1.013 1.012 1.011 2.5 Pressure Ratio (t/t)
No Control 12jets,0.2bar(0.47%m) 24jets,0.2bar(0.88%m) 12jets,0.47bar(0.75%m)

3 3.5 4 4.5 Corrected mass flow rate (kg/s)

20

10% increase in surge margin for 0.6% engine massflow

surge Margin increase (%)

15 10 5 0 0 0.5 1 1.5

Injected mass flow/compressor mass flow (%)

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MEMS Flow Sensors

Tungsten resistor ~300nm Resistor leads

Silicon nitride top layer 1m

Polyimide 6m Silicon oxide 0.6m Low resistivity silicon 250m Silicon oxide 0.3m
Through wafer connections

Membrane cavity

Designed for robustness, sensitivity, good frequency response 10 x sensitivity of conventional stick-on hot film, 30 kHz cut-off
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MEMS Pulse-Jet Flow Actuator

3mm 45 skewed, 200m dia hole Pulsed jet, 100 - 200 m/s 5-20% duty cycle 200m diameter

Pressurised supply (30-80 kPa)

PZT cantilever actuator 50-100 m displacement 1-2kHz frequency

Robust, High authority (force & disp.), Small footprint and thickness.
Modelling and simulation
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MEMS Microvalve Development

400.00 350.00 Jet volocity (ms-1) 300.00 250.00 200.00 150.00 100.00 50.00 0.00 0 200 400 600 800 1000 Frequency (Hz)
30kPa 50kPa 80kPa 100kPa

Top PZT layer Titanium shim Bottom PZT layer Wax PZT support for machining (2mm thick)

Microfabrication development
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High Reynolds No. Demonstrations

Model 2D H8Y in NWB Braunschweig

ONERA F1 Wind Tunnel

Reynolds number 6.5 x106 M=0.2

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High Reynolds No. demonstrations

Flap LE Separation Separation Flap LE

Flap TE

Flap TE URANS Simulation

URANS Simulation

Unactuated

Actuated

Flow Separation delayed from 30% to 90% off flap chord

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High-lift benefits
Baseline TE Control TE+LE Control

CL

CL =0,2

AOA (deg)

Impact of applying pulsed jet actuation to LE and TE devices on an optimised civil transport wing derived from ONERA & DLR test programmes
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Summary of Achievements - Demonstrated flow separation delay using active, distributed microsystems under flight scale conditions. - Developed/demonstrated first-pass flush mounted flow sensors and high authority flow actuators - Identified a number of relatively near-term applications - Intakes - High Lift - Turbomachine compressors - Developed/validated modelling capabilities for simple subboundary layer actuator concepts

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Outstanding Issues
- Technology still relatively immature with regard to achieving all theoretically possible benefits - However, limited application could be conceivable - perhaps for flow separation control
high lift system performance improvement Turbomachine compressors Intake performance improvement unconventional flight controls (compliant aerodynamics)

- Still need to address many practical issues regarding implementation:

- Robustness, system integration, maintenance & repair, cost/benefit assessment, certification.

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Questions?

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