When Roughness Matters – Engineered Microstructures for Cruise Efficiency and Drag Reduction
Isaac Choutapalli (Department of Mechanical Engineering, UTRGV)
Surface roughness is often seen as a performance penalty, but when engineered at the right scale and geometry, it can become a powerful passive flow-control tool. We explored two microstructured strategies aimed at AFRL-relevant missions: enhancing cruise efficiency of lifting surfaces and reducing skin-friction drag on non-lifting surfaces.
For lifting surfaces, we designed owl-inspired airfoils combining leading-edge tubercles, chordwise micro-barbules (100 µm high, 0.5 mm spacing), and a trailing-edge Gurney flap. Across Reynolds numbers from 69,000 to 138,000, these modifications consistently improved lift-to-drag ratio in the 2–5 degrees cruise AoA band, increased peak lift by up to ~25%, and preserved trim at cruise. At higher Re, they formed a distinct aerodynamic family with stronger lift carry-on toward stall, providing both efficiency and maneuver margin.
For non-lifting surfaces, we tested triangular porous texturing (TPT) on a zero-pressure-gradient flat plate using PIV. Our previous studies at lower Re showed solid micro-prisms achieved ~19% skin-friction reduction by slip-cutting high-speed streaks, while porous TPT sacrificed a small amount of drag reduction (~15%) to deliver +120% momentum flux via passive bleed - offering stall resistance capability. Experiments are underway to investigate these outcomes at higher Re. CFD simulations of the flat-plate flows are also underway to study how these geometries redistribute wall-normal momentum and shear, to enable informed tuning of microstructure parameters to target either drag minimization or flow separation control.
Together, the results show that “roughness,” when designed with purpose, can serve as an enabler of efficiency and control across a range of aerodynamic applications.