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Vehicle thermal protection is an important aspect of the overall vehicle development process. It involves optimizing the exhaust system routing and designing heat shields to protect various components that are in near proximity to the exhaust system. Reduced time to market necessitates an efficient process for thermal protection development. A robust procedure that utilizes state of the art CFD simulation techniques proactively during the design phase is described. Simulation allows for early detection of thermal issues and development of countermeasures several months before prototype vehicles are built. Physical testing is only used to verify the thermal protection package rather than to develop heat shields. The new procedure reduces the number of physical tests and results in a robust, efficient methodology.

Avoiding low-frequency pressure pulsations and establishing a good axial static pressure distribution are primary concerns for open jet wind tunnels. The current research was conducted to ensure the full scale Chrysler Aero-Acoustic Wind Tunnel (AAWT) design is consistent with good performance in these two areas. Experiments were conducted in two tunnels: a 1/3.6-scale closed-circuit tunnel and a 1/12-scale open-loop tunnel. Results from both are consistent, and a configuration that exhibits i) minimal pulsations for both empty test section and 15% vehicle blockage and ii) a good axial static pressure distribution has been identified for the AAWT. The results illustrate the effect of open jet length, collector geometry, and plenum geometry on pulsation levels and highlight the spatial variation of the pulsation levels within the plenum chamber. Pulsation levels were observed to increase with increasing open jet length and decreasing collector throat area.

Drag measurements are made on each of the members of 2, 3 & 4-vehicle platoons. One-eighth scale vehicle models are used in a wind tunnel equipped with a suction surface ground plane for boundary layer control. Strong interaction between vehicles takes place for spacings less than one vehicle length, leading to drag values substantially lower than for an isolated vehicle. All vehicles in the platoon experience lower drag. The average drag coefficient for a 4-vehicle platoon at a nominal spacing of 0.2 vehicle lengths is just 56 percent of the drag of the vehicle in isolation. It is also concluded that little additional benefit is achieved by forming platoons longer than 6-7 vehicles. Finally, the 2-vehicle platoons are operated in different orientations-front-to-front, back-to-back and reversed-to provide an estimate for drag reduction sensitivity to vehicle shape.

Wind tunnel tests are conducted using l/8th scale models of a standard U.S. mini-van to study the effect of inter-vehicle spacing on the drag of each of the vehicles in 2, 3 & 4-car platoons. The wind tunnel has a ground plane equipped with boundary layer control provided by means of suction over a homogeneously porous surface. Internal, 3-component force sensors are used to measure drag, side force, and yawing moment on each model. Drag coefficient of an individual vehicle alone is about 0.33. When spacing between platoon members is greater than about one vehicle length, the interaction among members is relatively weak. The drag of the lead vehicle is unaffected by the presence of other platoon members; each succeeding vehicle exhibits a lower drag coefficient. For spacings less than 1 vehicle length, drag coefficients are reduced for all members of the platoon, although the interior members experience the greater savings.