High Speed Systems Test (HSST)
Abstract
The HSST project continued to advance ground and flight test technologies, techniques, instrumentation, and modeling and simulation capabilities required for the development of hypersonic weapon systems. In FY22, HSST continued to address critical technology shortfalls for hypersonic test and evaluation in aerothermal and propulsion ground testing capabilities and advanced instrumentation to support hypersonic flight tests. Several other technology development efforts also progressed throughout the year. To address the technology shortfall involving aerothermal and propulsion testing, HSST is developing a new test facility that utilizes clean-air heat addition (non-vitiated air) and a variable Mach number nozzle (VMN) capability to provide the representative high-temperature conditions for characterizing weapon systems, including air-breathing propulsion capabilities. The clean-air heat addition is especially important to the characterization of air-breathing propulsion systems, as previous HSST efforts demonstrated that vitiated air provides different gas properties than clean air found in the atmosphere and thus is not representative of what the vehicle would experience in flight. This significantly affects the engine’s performance and operability in the test environment and results in erroneous flight predictions. Additionally, characterization of advanced sensors for hypersonic systems also benefits from clean-air heat addition as it provides a more representative environment for the sensor to operate in. The variable Mach number capability provides a more representative trajectory simulation for the system under test, permitting more accurate predictions before conducting flight tests. Assembly of the new test facility, called the Hypersonic Aerothermal and Propulsion Clean-Air Testbed (HAPCAT), was completed in FY 2022, enabling the plan for operational facility checkouts starting in FY 2023 to demonstrate the facility envelope and test techniques. Initial testing in HAPCAT will involve the characterization of advanced hypersonic sensors in a combined aerodynamic and aerothermal effects environment. All of the efforts associated with HAPCAT also serve as pathfinders for the development of a larger-scale, more capable facility at the AEDC. To address capacity constraints involved with aerothermal material characterization ground testing, HSST initiated a new aerothermal test technology development effort to prototype alternative high enthalpy test technologies, to include a plasmatron test capability. This effort involves the advancement of inductively-coupled plasma ground test facilities that can serve as a complement to arc-jet heater capabilities. Significant progress was achieved in the development of the SkyRange capability, an unmanned aerial vehicle-based range to support hypersonic flight tests and other missions for the Department of Defense. SkyRange provides a more agile, flexible, and cost-effective method for providing support to long-range hypersonic flight tests with increased data collection capabilities beyond the current state-of-the-art. It also addresses a critical throughput shortfall for supporting the number of hypersonic flight tests required, as a sufficient number of existing assets does not exist. RQ-4 Global Hawks and MQ-9 Reapers comprise the platforms used for SkyRange, taking advantage of their long-endurance, flexibility, and high-payload capability. SkyRange augments existing air, sea, and land test support assets referred to as the “string of pearls,” reducing the high costs associated with traditional flight test support and increasing mission flexibility. Novel sensor suites are being developed in the areas of telemetry capture and relay, multispectral imaging, atmospheric sensing, terminal scoring, and other areas to aid in the development of hypersonic systems. Several of these sensors are being developed through HSST for integration into the SkyRange capability. Achievements were made for both SkyRange aircraft platforms in FY 2022. Three RQ-4s were fully modified into a SkyRange configuration, called RangeHawks, making them available for sensor suite integration. Two of these RangeHawks were equipped with advanced phased-array telemetry antennas and provided data collection support to multiple hypersonic flight test missions. Additional RQ-4s were added to the SkyRange RangeHawk fleet by leveraging Air Force divestments in operational RQ-4 aircraft. SkyRange initiated conversion of the additional RQ-4 platforms into the RangeHawk configuration. Throughout FY 2022, the RangeHawks completed several milestones, including the first simultaneous operation of two RangeHawks, the first simultaneous operation of two sensor suites on two RangeHawks, and the first deployment of two RangeHawks to a forward operating location. For the MQ-9s, five aircraft were stationed at the main operating base in California. These MQ-9s, called RangeReapers, will be used for integrating various sensors, generally through the use of pylon-carried pods. Necessary agreements to enable flight operations were established with multiple entities, paving the way for the first flight operations as a part of SkyRange in FY 2023. The development, integration, and operation of multiple phased-array telemetry capabilities continued as part of SkyRange in FY 2022. One variant was integrated and operated on two RangeHawks, achieving initial operating capability by successfully collecting data during long range missile flight tests. These telemetry antennas will continue to support flight test missions in FY 2023. A second variant was fully fabricated in FY 2022 and is planned for integration onto a RangeHawk in FY 2023. A third variant that will be developed for both RangeHawks and RangeReapers will continue design and fabrication and is scheduled for integration onto both SkyRange platforms in FY 2023. RangeLynx module installation was completed on all three RangeHawks in FY 2022, providing real-time, secure satellite-based telemetry and data relay to ground stations and other SkyRange assets. RangeLynx will also be integrated onto RangeReapers by including the modules in the sensor suite pods. Progress continued on the development of a high-fidelity automated and reconfigurable multispectral imaging tracking system for integration into an RQ-4 Global Hawk as part of the overall SkyRange capability. Fabrication of the system was completed and an initial fit-check on a RangeHawk was successfully executed, enabling a planned installation of the system in FY 2023. Ground checkouts were successfully completed in preparation for full installation as well. The High-Altitude LIDAR Atmospheric Sensing (HALAS) system for improved atmospheric measurements continued to make progress in FY 2022. A version installed on a Gulfstream G-IV performed multiple airborne data collection missions as part of a technology risk reduction effort for the eventual HALAS system for the RangeHawk. The RangeHawk variant completed its critical design review and progressed to full fabrication. Additional upgrades and technology development continued at the CUBRC hypersonic shock and expansion wind tunnels to support hypersonic ground testing. These included the design and integration of an aero-optic instrumentation suite to enable the evaluation of sensor and seeker systems for hypersonic vehicles, the initial conceptual design of a jet interactions test capability using the CUBRC facilities, and the continued development of a fast-response force and moment balances for use in the CUBRC facilities. In addition to these upgrades, a new wave rotor facility development continued. Progress with this new facility included the successful development and demonstration of a small-scale pathfinder facility that provided critical risk reduction to the full-scale facility and the initial development of the full-scale facility at its chosen location at the CUBRC site. This facility will provide important test capabilities for aero-optic and aerothermal ground testing required for hypersonic weapon system development.
Document Details
- Document Type
- Accomplishment
- Publication Date
- Oct 01, 2024
- Source ID
- adbac18da3fbd8766aeadefee0ede6de