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Tests to investigate and document leading-edge and runback propeller ice accretions in
Appendix C icing conditions, as well as an attempt to approximately duplicate a propeller ice
accretion from a Mitsubishi MU-2B flight test propeller which experienced full-span ice
accretion in suspected supercooled large drop (SLD) icing conditions were conducted in the
McKinley climactic chamber, Eglin AFB, in November 2006. This paper reviews the test
objectives, setup, and resulting data.
Nomenclature
AoA
hp
KTAS
LWC
MVD
OAT
RPM
SLD
VDC
Ac
0
n0
K0
=
=
=
=
=
=
=
=
=
=
=
=
=
angle of attack,
horse power
knots true air speed
liquid water content, g/m3
median volumetric diameter, m
outside air temperature, F
revolutions per minute
supercooled large drop
Volt direct current
accumulation parameter
collection efficiency
freezing fraction
modified droplet inertia parameter
I. Introduction
This paper provides an overview of a propeller icing wind tunnel test conducted to investigate and document ice
accretions on a full-scale propeller. The test was conducted in the McKinley Climatic Laboratory, at Eglin Air Force
Base, Florida. It was a collaborative effort of the Federal Aviation Administration (FAA) Aircraft Icing Research
program, FAA Aircraft Certification Service, United States Air Force (USAF), Hartzell Propeller, Inc., MT
Propeller Company, Goodrich Corporation, McCauley Propeller, and Hamilton Sundstrand. Several other people
and companies were instrumental in completing this work. They include Aerospace Testing Engineering &
Certification (AeroTEC), Intercontinental Jet Services Incorporated L.L.C., RS Information Systems (RSIS), Dr.
Andy Broeren, and Dr. David Anderson.
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This material is declared a work of the U.S. Government and is not subject to copyright protection in the United States.
During a recent flight test in an MU-2B in natural icing conditions, the aircraft experienced unexpected fullspan propeller icing. During the icing encounter, the airspeed decayed dramatically, losing 40 knots in 1 minute and
25 seconds1. Airframe ice accretion was deemed to be small by the flight crew. A postflight analysis of in-flight
video showed ice accretion along the entire span of the propeller blades. See Fig. 1. In-service experience of one
transport airplane indicated that propeller runback ice was a significant problem for a certain outside air temperature
(OAT) range, requiring redesign of the propeller ice protection system2.
Very little information on propeller icing is available in the public sector. The primary sources of experimental
data are still the papers by Preston and Blackman published in 19483 and Neel and Bright published in 19504. Both
of these reports document propeller performance losses for a research aircraft flying in natural icing conditions. Ice
accretion characteristics are not documented. No data from controlled testing in a ground icing facility is available.
2.
3.
4.
5.
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C. Icing Conditions
Target liquid water content (LWC) and median volumetric diameter (MVD) could not be measured during the
test runs. The LWC and MVD were achieved by setting, monitoring, and recording water flow rate and atomizing
air pressure on the spray system. Calibration runs were performed before the test to determine proper water flow
and air pressure combinations needed to achieve the desired LWC and MVD required for each test point. Wind
speed could not be measured during the test, therefore, it was based on the pretest calibration of the fan speeds in the
wind tunnel. Chamber static temperature and humidity were monitored and recorded. The velocity profile along the
radius of the open jet core was measured. There was some reduction after about 75%, radius but it was determined
to be acceptable for the test. A grid was used to show the cloud spray was uniform.
D. Imaging
After each test run, the resultant ice shapes were photographed using a 13.5-Mega-pixel digital camera. Highspeed stop action video was taken during the test runs. Two high-speed cameras were used; one recorded images of
an entire propeller blade while the other recorded close-up images of the boot area of one propeller blade. Both of
the cameras were housed in enclosures to prevent ice accumulation and minimize wind vibration. The camera
synchronizing was done by triggering the cameras with the standard pulse signal output normally used for propeller
synchronization. The propeller blades were illuminated using four Arri 1200-watt compact (Hydrargyrum mediumarc iodide) HMI lamps. See Fig. 5 for camera and light placement.
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F. Test Articles
During the test, we had planned to use five different propellers on two different engines. These test articles are
listed in Table 1.
Table 1. Planned test articles
Maximum
Engine Prop RPM
TIO-5402500
J2BD
TPE33110-511M
1591
Propeller
Blades
2aluminum
3composite
4composite
4aluminum
Propeller
Manufacturer
Hartzell
Propeller
Hartzell
Propeller
MT Propeller
Hub
HC-I2YR-1BF
Blade
F8074
Deicing
Schedule
90/90
HC-I3YR-1E
7890K
90/90
MTV-14-B
195-30a
Hartzell
Propeller
HC-B4TN5( )L
LT10282NSB5.3R
MT Propeller
MTV-27-1-E-CF-R(G)
CFRL250-55
90/90;
continuous
34/34/68;
10/60;20/60;
90/90
continuous
5composite
Due to delays in the setup, the amount of time allotted for testing was reduced from an original 12 days to 7
days. As a result, the reciprocating engine (TIO-540-J2BD) and associated propellers were not tested, and ice
accretion, as a function of RPM, could not be evaluated. All the test configurations of the TPE331-10-511M
turboporop engine were accomplished with the exception of those with 10/60 and 20/60 deicing schedules.
The five-blade composite MT propeller was a new propeller. The Hartzell four-blade aluminum propeller was
made up of both new and used blades to evaluate the effects of surface roughness on ice adhesion due to normal
blade erosion in service. Blades in the same condition, new or service condition, were opposite one another. The
blades were numbered for identification. Blades #2 and #4 were new blades, and blades #1 and #3 were service
condition blades. Blade #1 had light paint erosion at the extreme leading edge with no other wear. Blade #3 had
slightly more erosion than blade #1. Both service condition blades were considered to be in above average condition
for mid-time blades (1,468 hours into a 3,000 flight-hour overhaul interval) See Fig. 6.
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Deice Boot
P/N
Goodrich
4E1188-7
MT
TBD
Goodrich
4E2837-10
Deice timing
(sec)
34/34/68
Deice Schedule
Continuous
Inboard zone/outboard
zone
All blades
90/90
Opposing blades
The first test article represented the configuration of the Mitsubishi MU-2B airplane. The second configuration
did not represent any specific aircraft. The third test represents the certificated configuration of several airplanes
currently in service.
Deicing power was supplied by a 28-Volt direct current (Vdc) power supply. The power to the boots was turned
on and off using computer-controlled relays so that various timing sequences could be used during the test. The
wiring, brush blocks, slip ring, and relays were standard equipment found on an MU-2B. The MT propeller had a
slip ring that mated with the existing brush blocks. Voltage was measured between the relays and the brush blocks
to confirm that the boot was not only on but was also getting the correct voltage.
G. Test Matrix
The test setup lasted several days longer than had been scheduled. As a result, the test matrix had to be
substantially truncated and revised. Consequently, some objectives, such as icing as a function of RPM and
evaluation of scaling, were not met. A summary of the truncated test matrix is shown in Table 3.
Table 3. Test matrix used during test
RUN
No.
16
15
21
18
15A
15B
21A
3A
3B
4A
21B
19A
21C
4B
4C
26A
26B
26C
25
24
24A
24B
LWC
(g/m3)
1.04
1.04
0.36
2.44
1.04
1.04
0.36
0.33
0.33
0.57
0.36
0.1
0.36
0.45
0.52
0.4
0.52
0.36
0.36
0.66
0.4
0.36
MVD
(m)
22
22
96
15
22
22
96
16.5
16.5
16.5
96
40
96
20
20
20
20
96
96
15
20
96
OAT
(F)
12
12
12
12
12
12
12
4.6
4.6
15.2
24
12
12
12
22
12
22
24
24
19
12
12
RPM
1480
1480
1450
1520
1520
1600
1600
1450
1480
1520
1540
1535
1540
1560
1520
1485
1520
1520
1600
1596
1595
1530
TORQUE
(%)
23
30
23
21
33
38
45
39
34
42
36
35
39
36
33
40
42
42
50
42
45
36
BETA
ANGLE
()
24.5
25
25.1
24.6
26.6
26
26.2
26.2
26.2
26.2
26.2
26.2
26.2
26.2
26.7
15.2
15.2
15.2
26.2
26.2
26.2
26.1
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DEICE
TIMER
34/34/68
34/34/68
34/34/68
34/34/68
NO DATA
34/34/68
34/34/68
34/34/68
34/34/68
34/34/68
34/34/68
34/34/68
34/34/68
34/34/68
34/34/68
Continuous
Continuous
Continuous
90/90
90/90
90/90
90/90
TIME
(Min.)
11.75
14.17
11.5
0.65
14
15.53
12.42
10.58
4.25
11.88
11.98
15.02
13.57
14.57
13.9
14.07
14.58
13.6
13.62
15.02
17.33
11.23
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Composite
Thrust Reduction
10.0%
10.5%
10.8%
Corresponding
Metallic run
4B
4C
21B
Metallic
Thrust reduction
7.5%
2.26%
11.3%
The resultant ice shapes were similar between the two blade materials. See Figures 8-10. However, on run 26B,
the final ice shape was thicker and extended further to the tip than on run 4C, which accounts for the greater thrust
loss. One possible explanation for this difference is that the LWC did not match between the two runs. Run 26B
had an LWC of 0.52 g/m3, while run 4C had a LWC of 0.45 g/m3.
The stop action video data showed that, in all three cases, the extent of icing and shed rates were similar between
the composite and metallic propeller. Run 26B appeared to be further into a shed cycle than Run 4C, which could
also help account for the final ice shape differences and the greater reduction in thrust.
As a rule, ice shedding frequency seemed to be independent of the propeller and deicers tested, and averaged a
shed every 3-4 minutes on all test runs. Post flight inspection revealed that the blades did not all shed at once, and a
blade shed event was not apparent on the real-time thrust data.
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Figure 10. Run 26C (composite, lower) vs. Run 21B (metallic, upper).
B. Blade Condition
There was no noticeable difference between the ice shape location and shedding frequency due to blade
condition. Figure. 11 shows the similarities in ice shapes on a typical run. The blade numbers are written on the
tips of the propeller with either an O to indicate an in service blade or an N to indicate a new blade.
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Figure 11. Comparison of old vs. new blade on a typical test run.
were higher than the Appendix C icing conditions tested. The ice accretion and estimated propeller efficiency loss
of the MU-2B flight test event were approximately duplicated. See Fig. 12.
E. Thrust
Thrust values were recorded continuously. The propeller thrust was comparable to the drag of the test stand,
while at test condition, as a result, the measured thrust was low. On several of the early runs, this resulted in the
measured thrust reducing to zero midway through the run. To overcome this limitation, the engine was run up to
100% torque to measure thrust values just before each test began and again immediately after each test. The thrust
reductions shown in Table 5 were determined by comparing the thrust measurements taken at 100% torque. The
thrust reductions for the SLD runs averaged 13.4% and had a maximum of 21.2%. The thrust reductions for
Appendix C conditions averaged 5.9% and had a maximum of 13.4%.
Table 5. Thrust reductions at maximum power using Hartzell stand drag correction
Deicer
34/34/68
Continuous
90/90
SLD 12F
21.2%
16.6%
SLD 24F
11.3%
10.8%
9.0%
Appendix C
13.4%
10.5%
5.6%
A nominal thrust penalty on the order of 10% for Appendix C icing certification is proposed, unless another
value can be substantiated. Earlier independent flight test results3,4 suggest a value of 10% would cover most
Appendix C icing encounters.
V. Conclusion
The full-scale propeller icing test documented in this paper provides a unique and extensive data set for the study
of propeller icing. In addition to the numerical data, the exceptional imaging data obtained makes a valuable
contribution to the documentation of propeller icing. Detailed test data will be published in an FAA report6.
The test results support the assumption of a nominal thrust penalty on the order of 10% for icing certification.
Another important result was that by simulating supercooled large drop (SLD) conditions, it was possible to
approximately match a nearly full blade span photographed during flight test in suspected SLD conditions.
Additional research should be accomplished to complete the objectives originally planned and to develop
analytical tools that will allow propeller performance prediction for a given icing condition and deicing design.
These would include:
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Conduct additional propeller icing tests to complete the original test objectives. Evaluation of runback ice
accretions may be combined with research on other applications that use thermal deicing systems, such as
rotorcraft blades and fixed airfoils.
Conduct additional tests to measure thrust stand drag due to ice in Appendix C conditions.
Empirically measure lift and drag of propeller sections with ice shapes, simulating the accretions observed
in this test, and calculate propeller efficiency losses with the measured lift and drag.
Acknowledgments
Several organizations and individuals contributed to the planning, implementation, or reporting of the test.
Without their dedicated efforts, the value of the test program would not have been fully realized. Not all can be
recognized here, but the authors would like to acknowledge the contributions of Brian Meyer and his colleagues
from Hartzell Propeller, Gerd Muehlbauer and his colleagues from MT Propeller, Mr. Alan Farhner and his
colleagues from Goodrich, Dwayne Bell and his outstanding team at McKinley Climatic Laboratory, Lee Human
and his colleagues at AeroTEC, Mark James and his colleagues from Intercontinental Jet, Mr. Vincent Reich and
his colleagues from RSIS, Dr. David Anderson of the Ohio Aerospace Institute, and Dr. Andy Broeren of the
University of Illinois at Urbana-Champaign.
References
1
Timmons, L., Icing Investigations and Product Development on MU-2B Airplanes, SAE 2003-01-2088, presented at FAA
In-Flight Icing/ Ground De-icing International Conference, Chicago, IL, June 16-20, 2003.
2
Rodling, S., Experience From a Propeller Icing Certification, presentation at the SAE Aircraft Icing Committee meeting
in Zurich, Switzerland, September 18-20, 1989
3
Preston, G. M. and Blackman, C.C., Effects of Ice Formations on Airplane Performance in Level Cruising Flight, NACA
TN 1598, May 1948.
4
Broeren, Neel, C. B., Jr. and Bright, L. G., The Effect of Ice Formations on Propeller Performance, NACA TN 2212,
October 1950.
5
Ice Protection Harmonization Working Group, Task 2 Working Group Report on Supercooled Large Droplet Rulemaking,
September 2005
6
Pellicano, P., Dumont, C., Smith, T., Riley, J., Bell, D., and Reinhardt, E., Data From a Full-Scale Propeller Icing Test,
FAA report, to be published.
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