A numerical optimization of high altitude testing facility for wind tunnel experiments

High altitude test facilities are required to test the high area ratio nozzles operating at the upper stages of rocket in the nozzle full flow conditions. It is typically achieved by creating the ambient pressure equal or less than the nozzle exit pressure. On average, air/GN2 is used as active gas for ejector system that is stored in the high pressure cylinders. The wind tunnel facilities are used for conducting aerodynamic simulation experiments at/under various flow velocities and operating conditions. However, constructing both of these facilities require more laboratory space and expensive instruments. Because of this demerit, a novel scheme is implemented for conducting wind tunnel experiments by using the existing infrastructure available in the high altitude testing (HAT) facility. This article presents the details about the methods implemented for suitably modifying the sub-scale HAT facility to conduct wind tunnel experiments. Hence, the design of nozzle for required area ratio A/A∗, realization of test section and the optimized configuration are focused in the present analysis. Specific insights into various rocket models including high thrust cryogenic engines and their holding mechanisms to conduct wind tunnel experiments in the HAT facility are analyzed. A detailed CFD analysis is done to propose this conversion without affecting the existing functional requirements of the HAT facility.