A scaled version of the APT70 drone rotor, typical of small to medium UAV rotors, was tested in a 9-meter-high cold chamber for a wide range of icing parameters. The drone rotor used has four blades with varying chord and twist settings. The objective of this study was to investigate icing effects on the rotor aerodynamic performance, based on experimental data, for varying rotor speeds, precipitation rates, droplet sizes and air temperatures. Aerodynamic loads were measured using the built-in load cell, and data were compared to photographs taken during testing as well as ice thickness measurements at the end of tests. The impact of each test parameter and their variations on the degradation of the rotor’s performances was evaluated. The results show that larger droplets and lower RPMs and pitch angles generate a more rapid degradation of the performances due to the airflow around the blades and tip-vortex affecting the collection efficiency of the blades. With the smaller droplets, the air temperature did not affect the performance degradation, only the type of ice accumulation. However, with the larger droplets, degradation of the performances was less severe at warmer temperatures since almost no ice accumulated at the tip and droplets were expelled before freezing.

The objective of this research project is divided in four parts: (1) to design a piezoelectric actuator-based de-icing system integrated to a flat plate experimental setup and develop a numerical model of the system with experimental validation, (2) use the experimental setup to investigate actuator activation with frequency sweeps and transient vibration analysis, (3) add ice layer to the numerical model and predict numerically stresses for different ice breaking with experimental validation, and (4) bring the concept to a blade structure for wind tunnel testing. This paper presents the first objective of this study. First, preliminary numerical analysis was performed to gain basic guidelines for the integration of piezoelectric actuators in a simple flat plate experimental setup for vibration-based de-icing investigation. The results of these simulations allowed to optimize the positioning of the actuators on the structure and the optimal phasing of the actuators for mode activation. A numerical model of the final setup was elaborated with the piezoelectric actuators optimally positioned on the plate and meshed with piezoelectric elements. A frequency analysis was performed to predict resonant frequencies and mode shapes, and multiple direct steady-state dynamic analyses were performed to predict displacements of the flat plate when excited with the actuators. In those steady-state dynamic analysis, electrical boundary conditions were applied to the actuators to excite the vibration of the plate. The setup was fabricated faithful to the numerical model at the laboratory with piezoelectric actuator patches bonded to a steel flat plate and large solid blocks used to mimic perfect clamped boundary condition. The experimental setup was brought at the National Research Council Canada (NRC) for testing with a laser vibrometer to validate the numerical results. The experimental results validated the model when the plate is optimally excited with an average of error of 20% and a maximal error obtained of 43%. However, when the plate was not efficiently excited for a mode, the prediction of the numerical data was less accurate. This was not a concern since the numerical model was developed to design and predict optimal excitation of structures for de-icing purpose. This study allowed to develop a numerical model of a simple flat plate and understand optimal phasing of the actuators. The experimental setup designed is used in the next phase of the project to study transient vibration and frequency sweeps. The numerical model is used in the third phase of the project by adding ice layers for investigation of vibration-based de-icing, with the final objective of developing and integrating a piezoelectric actuator de-icing system to a rotorcraft blade structure.

A four-year project investigating the use of piezoelectric actuators as a vibration-based low power de-icing system has been initiated at the Anti-Icing Materials Laboratory. The work done preceding this investigation consisted of studying, numerically and experimentally, the system integration to a flat plate structure, the optimal excitation of the system, the resonant structural modes and the shear stress amplitudes to achieve de-icing for that structure. In this new investigation, the concepts and conclusions obtained on the flat plate structure were used to design and integrate the system into a rotating blade structure. An experimental setup was built for de-icing tests in rotation within an icing wind tunnel, and a finite-element numerical model adapted to the new geometry of the blade was developed based on the expertise accumulated using previous flat plate structure analysis. Complete de-icing of the structure was obtained in the wind tunnel using the developed de-icing system, and its power consumption was estimated. The power consumption was observed to be lower than the currently used electrothermal systems. The finite-elements numerical model was therefore used to study the case of a full-scale tail rotor blade and showed that the power reduction of the system could be significantly higher for a longer blade, confirming, therefore, the relevance of further de-icing investigations on a full-scale tail rotor.

Successful icing/de-icing simulations for rotorcraft require a good prediction of the convective heat transfer on the blade’s surface. Rotorcraft icing is an unwanted phenomenon that is known to cause flight cancelations, loss of rotor performance and severe vibrations that may have disastrous and deadly consequences. Following a series of experiments carried out at the Anti-icing Materials International Laboratory (AMIL), this paper provides heat transfer measurements on heated rotor blades, under both the anti-icing and de-icing modes in terms of the Nusselt Number (Nu). The objective is to develop correlations for the Nu in the presence of (1) an ice layer on the blades (Nu_Ice) and (2) liquid water content (LWC) in the freestream with no ice (Nu_Wet). For the sake of comparison, the Nu_Wet and the Nu_Ice are compared to heat transfer values in dry runs (Nu_Dry). Measurements are reported on the nose of the blade-leading edge, for three rotor speeds (Ω) = 500, 900 and 1000 RPM; a pitch angle (θ) = 6°; and three different radial positions (r/R), r/R = 0.6, 0.75 and 0.95. The de-icing tests are performed twice, once for a glaze ice accretion and another time for rime ice. Results indicate that the Nu_Dry and the Nu_Wet directly increased with V_∝, r/R or Ω, mainly due to an increase in the Reynolds number (Re). Measurements indicate that the Nu_Wet to Nu_Dry ratio was always larger than 1 as a direct result of the water spray addition. Nu_Ice behavior was different and was largely affected by the ice thickness (t_ice) on the blade. However, the ice acted as insulation on the blade surface and the Nu_Ice to Nu_Dry ratio was always less than 1, thus minimizing the effect of convection. Four correlations are then proposed for the Nu_Dry, the Nu_Wet and the Nu_Ice, with an average error between 3.61% and 12.41%. The Nu_Dry correlation satisfies what is expected from heat transfer near the leading edge of an airfoil, where the Nu_Dry correlates well with Re^0.52.

In order to study ice protection systems for rotating blades, a new experimental setup has been developed at the Anti-Icing Materials International Laboratory (AMIL). This system consists of two small-scale rotating blades in a refrigerated icing wind tunnel where atmospheric icing can be simulated. Power is brought to the blades through a slip ring, through which the signals of the different sensors that are installed on the blades also pass. As demonstrated by the literature review, this new setup will address the need of small-scale wind tunnel testing on electrically powered rotating blades. To test the newly designed apparatus, preliminary experimentation is done on a hybrid ice protection system. Electrothermal protection is combined with different surface coatings to measure the impact of those coatings on the power consumption of the system. In anti-icing mode, the coatings tested did not reduce the power consumption on the system required to prevent ice from accumulating on the leading edge. The coatings however, due to their hydrophobic/superhydrophobic nature, reduced the power required to prevent runback ice accumulation when the leading edge was protected. One of the coatings did not allow any runback accumulation, limiting the power to protect the whole blades to the power required to protect solely the leading edge, resulting in a potential 40% power reduction for the power consumption of the system. In de-icing mode, the results with all the substrates tested showed similar power to achieve ice shedding from the blade. Since the coatings tested have a low icephobicity, it would be interesting to perform additional testing with icephobic coatings. Also, a small unheated zone at the root of the blade prevented complete ice shedding from the blade. A small part of the ice layer was left on the blade after testing, meaning that a cohesive break had to occur within the ice layer, and therefore impacting the results. Improvements to the setup will be done to remedy the situation. Those preliminary testing performed with the newly developed test setup have demonstrated the potential of this new device which will now allow, among other things, to measure heat transfer, force magnitudes, ice nucleation, and thermal equilibrium during ice accretion, with different innovative thermal protection systems (conductive coating, carbon nanotubes, impulse, etc.) as well as mechanical systems. The next step, following the improvements, is to measure forced convection on a thermal ice protection system with and without precipitation and to test mechanical ice protection systems.

The objective of this research project is divided in four parts: (1) to design a piezoelectric actuator-based de-icing system integrated to a flat plate experimental setup and develop a numerical model of the system with experimental validation, (2) use the experimental setup to investigate actuator activation with frequency sweeps and transient vibration analysis, (3) add an ice layer to the numerical model and predict numerically stresses at ice breaking with experimental validation, and (4) bring the concept to a blade structure for wind tunnel testing. This paper presents the third part of the investigation in which an ice layer is added to the numerical model. Five accelerometers are installed on the flat plate to measure acceleration. Validation of the vibration amplitude predicted by the model is performed experimentally and the stresses calculated by the numerical model at cracking and delamination of the ice layer are determined. A stress limit criteria is then defined from those values for both normal stress at cracking and shear stress at delamination. As a proof of concept, the numerical model is then used to find resonant modes susceptible to generating cracking or delamination of the ice layer within the voltage limit of the piezoelectric actuators. The model also predicts a voltage range within which the ice breaking occurs. The experimental setup is used to validate positively the prediction of the numerical model.