The Effect of Thermal Barrier Coating Surface Temperature on the Adhesion Behavior of CMAS Deposits

2020 ◽  
Author(s):  
Robert A. Clark ◽  
Nicholas Plewacki ◽  
Pritheesh Gnanaselvam ◽  
Jeffrey P. Bons ◽  
Vaishak Viswanathan
Keyword(s):  
Heat Transfer ◽  
High Pressure ◽  
Surface Temperature ◽  
Mass Flow ◽  
Experimental Results ◽  
Thermal Barrier ◽  
Back Side ◽  
Surface Temperatures ◽  
The Impact ◽  
Side Flow

Abstract The interaction of thermal barrier coating’s surface temperature with CMAS (calcium magnesium aluminosilicate) like deposits in gas turbine hot flowpath hardware is investigated. Small Hastelloy X coupons were coated in TBC using the air plasma spray (APS) method and then subjected to a thermal gradient via back-side impingement cooling and front-side impingement heating using the High Temperature Deposition Facility (HTDF) at The Ohio State University (OSU). A 1-D heat transfer model was used to estimate TBC surface temperatures and correlate them to intensity values taken from infrared (IR) images of the TBC surface. TBC frontside surface temperatures were varied by changing back-side mass flow (kept at a constant temperature), while maintaining a constant hot-side gas temperature and jet velocity representative of modern commercial turbofan high-pressure turbine (HPT) inlet conditions (approximately 1600K and 200 m/s, or Mach 0.25). In this study, Arizona Road Dust (ARD) was utilized to mimic the behavior of CMAS attack on TBCs. To identify the minimum temperature at which particles adhere, the back-side cooling mass flow was set to the maximum amount allowed by the test setup, and trace amounts of 0–10 μm ARD particles were injected into the hot-side flow to impinge on the TBC surface. The TBC surface temperature was increased through coolant reduction until noticeable deposits formed, as evaluated through an IR camera. Accelerated deposition tests were then performed where approximately 1 gram of ARD was injected into the hot side flow while the TBC surface temperature was held at various points above the minimum observed deposition temperature. Surface deposition on the TBC coupons was evaluated using an infrared camera and a backside thermocouple. Coupon cross sections were also evaluated under a scanning electron microscope for any potential CMAS ingress into the TBC. Experimental results of the impact of surface temperature on CMAS deposition and deposit evolution and morphology are presented. In addition, an Eulerian-Lagrangian solver was used to model the hot-side impinging jet with particles at four TBC surface temperatures and deposition was predicted using the OSU Deposition model. Comparisons to experimental results highlight the need for more sophisticated modeling of deposit development through conjugate heat transfer and mesh morphing of the target surface. These results can be used to improve physics-based deposition models by providing valuable data relative to CMAS deposition characteristics on TBC surfaces, which modern commercial turbofan high pressure turbines use almost exclusively.

THE EFFECT OF THERMAL BARRIER COATING SURFACE TEMPERATURE ON THE ADHESION BEHAVIOR OF CMAS DEPOSITS

2021 ◽  
pp. 1-14
Author(s):  
Robert A. Clark ◽  
Nicholas Plewacki ◽  
Pritheesh Gnanaselvam ◽  
Jeffrey P. Bons ◽  
Vaishak Viswanathan
Keyword(s):  
High Pressure ◽  
Surface Temperature ◽  
Thermal Barrier Coating ◽  
Thermal Barrier ◽  
Back Side ◽  
Gas Temperature ◽  
Front Side ◽  
Barrier Coating ◽  
Inlet Conditions ◽  
Side Flow

Abstract The interaction of thermal barrier coating’s (TBC) surface temperature with CMAS (calcium magnesium aluminosilicate) like deposits in gas turbine hot flowpath hardware is investigated. Small Hastelloy X coupons were coated in TBC and then subjected to a thermal gradient via back-side impingement cooling and front-side impingement heating using the High Temperature Deposition Facility (HTDF) at The Ohio State University (OSU). TBC front-side surface temperatures were varied by changing a constant temperature back-side mass flow, while maintaining a constant hot-side gas temperature and jet velocity representative of modern commercial turbofan high-pressure turbine (HPT) inlet conditions (approximately 1600K and 200 m/s, or Mach 0.25). In this study, Arizona Road Dust (ARD) was utilized to mimic the behavior of CMAS attack on TBCs. Accelerated deposition tests were performed where approximately 1 gram of ARD was injected into the hot side flow while the TBC surface temperature was held at various points above the minimum observed deposition temperature. Surface deposition on the TBC coupons was evaluated using an infrared camera and a backside thermocouple. In addition, an Eulerian-Lagrangian solver was used to model the hot-side impinging jet AND deposition was predicted using the OSU Deposition model. These results can be used to improve physics-based deposition models by providing valuable data relative to CMAS deposition characteristics on TBC surfaces, which modern commercial turbofan high pressure turbines use almost exclusively.

Study of Impact of Gas Cooler Cooling Circuit on Heat Transfer Performance

2012 ◽  
Vol 236-237 ◽  
pp. 224-229
Author(s):  
Bing Qiang He ◽  
Chun Ling Liao
Keyword(s):  
Heat Transfer ◽  
Mass Flow ◽  
Heat Transfer Performance ◽  
Experimental Tests ◽  
Transfer Performance ◽  
Cell Type ◽  
Cooling Circuit ◽  
Transfer Processes ◽  
The Impact ◽  
Side Flow

Experimental study on the structure and characteristics of cooling circuit of full-aluminum parallel flow gas cooler. The experimental tests on the built cell-type and ternary GCMCPF are conducted. In the heat transfer processes of the cooler with different circuit structures, the impact of CO2 refrigerant side flow resistance and the mass flow on the heat transfer performance of gas cooler is measured. The results show that the ternary type GCMCPF structure can enhance the heat transfer for CO2 fluid at the weak heat transfer area in the cell-type GCMCPF. Within a certain range of mass flow, the former heat transfer is 1.5 times the later one, and the structural sizes of GCMCPF can be reduced in the same requirements for heat transfer.

Heat-Transfer Measurements and Predictions for the Vane and Blade of a Rotating High-Pressure Turbine Stage

2004 ◽  
Vol 126 (1) ◽  
pp. 101-109 ◽  
Author(s):  
Charles W. Haldeman ◽  
Michael G. Dunn
Keyword(s):  
Heat Transfer ◽  
High Pressure ◽  
Three Dimensional ◽  
Experimental Results ◽  
Thermal Barrier ◽  
Turbine Stage ◽  
High Pressure Turbine ◽  
Transfer Data ◽  
Commercial Code ◽  
Blade Tip

This paper describes heat-transfer measurements and predictions obtained for the vane and blade of a rotating high-pressure turbine stage. The measurements were obtained with the stage operating at design corrected conditions. A previous paper described the aerodynamics and the blade midspan location heat-transfer data and compared these experimental results with predictions. The intent of the current paper is to concentrate on the measurements and predictions for the 20%, 50%, and 80% span locations on the vane, the vane inner and outer endwall, the 20% and 96% span location on the blade, the blade tip (flat tip), and the stationary blade shroud. Heat-transfer data obtained at midspan for three different thermal-barrier-coated vanes (fine, medium, and coarse) are also presented. Boundary-layer heat-transfer predictions at the off-midspan locations are compared with the measurements for both the vane and the blade. The results of a STAR-CD (a commercial code) three-dimensional prediction are compared with the 20% and 96% span results for the blade surface. Predictions are not available for comparison with the tip and shroud experimental results.

scholarly journals Inverse Analysis of In-Cylinder Gas-Wall Boundary Conditions: Investigation of a Yttria-Stabilized Zirconia Thermal Barrier Coating for Homogeneous Charge Compression Ignition

2017 ◽  
Vol 139 (10) ◽  
Author(s):  
Ryan O'Donnell ◽  
Tommy Powell ◽  
Mark Hoffman ◽  
Eric Jordan ◽  
Zoran Filipi
Keyword(s):  
Heat Transfer ◽  
Heat Flux ◽  
Surface Temperature ◽  
Homogeneous Charge Compression Ignition ◽  
Engine Performance ◽  
Ex Situ ◽  
Thermal Barrier ◽  
Compression Ignition ◽  
The Impact ◽  
Homogeneous Charge

Thermal barrier coatings (TBCs) applied to in-cylinder surfaces of a low temperature combustion (LTC) engine provide an opportunity for enhanced efficiency via two mechanisms: (i) positive impact on thermodynamic cycle efficiency due to combustion/expansion heat loss reduction, and (ii) enhanced combustion efficiency. Heat released during combustion increases the temperature gradient within the TBC layer, elevating surface temperature over combustion-relevant crank angles. Thorough characterization of this dynamic temperature “swing” at the TBC–gas interface is required to ensure accurate determination of heat transfer and the associated impact(s) on engine performance, emissions, and efficiencies. This paper employs an inverse heat conduction solver based on the sequential function specification method (SFSM) to estimate TBC surface temperature and heat flux profiles using sub-TBC temperature measurements. The authors first assess the robustness of the solution methodology ex situ, utilizing an inert, quiescent environment and a known heat flux boundary condition. The inverse solver is extended in situ to evaluate surface thermal phenomena within a TBC-treated single-cylinder, gasoline-fueled, homogeneous charge compression ignition (HCCI) engine. The resultant analysis provides crank angle resolved TBC surface temperature and heat flux profiles over a host of operational conditions. Insight derived from this work may be correlated with TBC thermophysical properties to determine the impact(s) of material selection on engine performance, emissions, heat transfer, and efficiencies. These efforts will guide next-generation TBC design.

High Resolution Heat Transfer Measurements on the Stator Endwall of an Axial Turbine

2014 ◽  
Vol 137 (4) ◽  
Author(s):  
Benoit Laveau ◽  
Reza S. Abhari ◽  
Michael E. Crawford ◽  
Ewald Lutum
Keyword(s):  
Heat Transfer ◽  
Heat Transfer Coefficient ◽  
High Resolution ◽  
Surface Temperature ◽  
Transfer Coefficient ◽  
Mass Flow ◽  
Wall Temperature ◽  
Adiabatic Wall ◽  
Axial Turbine ◽  
The Heat Transfer Coefficient

In order to continue increasing the efficiency of gas turbines, an important effort is made on the thermal management of the turbine stage. In particular, understanding and accurately estimating the thermal loads in a vane passage is of primary interest to engine designers looking to optimize the cooling requirements and ensure the integrity of the components. This paper focuses on the measurement of endwall heat transfer in a vane passage with a three-dimensional (3D) airfoil shape and cylindrical endwalls. It also presents a comparison with predictions performed using an in-house developed Reynolds-Averaged Navier–Stokes (RANS) solver featuring a specific treatment of the numerical smoothing using a flow adaptive scheme. The measurements have been performed in a steady state axial turbine facility on a novel platform developed for heat transfer measurements and integrated to the nozzle guide vane (NGV) row of the turbine. A quasi-isothermal boundary condition is used to obtain both the heat transfer coefficient and the adiabatic wall temperature within a single measurement day. The surface temperature is measured using infrared thermography through small view ports. The infrared camera is mounted on a robot arm with six degrees of freedom to provide high resolution surface temperature and a full coverage of the vane passage. The paper presents results from experiments with two different flow conditions obtained by varying the mass flow through the turbine: measurements at the design point (ReCax=7.2×105) and at a reduced mass flow rate (ReCax=5.2×105). The heat transfer quantities, namely the heat transfer coefficient and the adiabatic wall temperature, are derived from measurements at 14 different isothermal temperatures. The experimental data are supplemented with numerical predictions that are deduced from a set of adiabatic and diabatic simulations. In addition, the predicted flow field in the passage is used to highlight the link between the heat transfer patterns measured and the vortical structures present in the passage.

Conjugate Heat Transfer Analysis on Generic Rim Seal Configurations in Rotor-Stator System

2018 ◽  
Author(s):  
Xingyun Jia ◽  
Liguo Wang ◽  
Qun Zheng ◽  
Hai Zhang ◽  
Yuting Jiang
Keyword(s):  
Heat Transfer ◽  
Mass Flow Rate ◽  
Mass Flow ◽  
Flow Rate ◽  
Conjugate Heat Transfer ◽  
Heat Transfer Analysis ◽  
Minimum Mass ◽  
Aerodynamic Efficiency ◽  
Axial Clearance ◽  
The Impact

Performance of generic rim seal configurations, axial-clearance rim seal (ACS), radial-clearance rim seal (RCS), radial-axial clearance rim seal (RACS) are compared under realistic working conditions. Conjugate heat transfer analysis on rim seal is performed in this paper to understand the impact of ingestion on disc temperature. Results show that seal effectiveness and cooling effectiveness of RACS are the best when compared with ACS and RCS, the minimum mass flow rate for seal of RACS is 75% of that of RCS, and 34.6% of ACS. Authors compare the disc temperature distribution between different generic rim seal configurations where the RACS seems to be favorable in terms of low disc temperature. In addition, RACS has higher air-cooled aerodynamic efficiency, minimizing the mainstream performance penalty when compared with ACS and RCS. Corresponding to the respective minimum mass flow rate for seal, the air-cooled aerodynamic efficiency of RACS is 23.71% higher than that of ACS, and 12.79% higher than the RCS.

Uncertainty Propagation Through a Simulation of Industrial High Pressure Die Casting

2019 ◽  
Vol 141 (11) ◽  
Author(s):  
Jiahong Fu ◽  
John Coleman ◽  
Gregory Poole ◽  
Matthew John M. Krane ◽  
Amy Marconnet
Keyword(s):  
Heat Transfer ◽  
High Pressure ◽  
Boundary Conditions ◽  
Die Casting ◽  
Uncertainty Propagation ◽  
Model Parameters ◽  
High Pressure Die Casting ◽  
Output Uncertainty ◽  
Pressure Die Casting ◽  
The Impact

Abstract While numerical models are often used in industry to evaluate the transport phenomena in solidification processes, the uncertainty in the results propagated from uncertain input parameters is rarely considered. In this work, in order to investigate the effects of input uncertainty on the outputs of high pressure die casting (HPDC) simulations, the Center for Prediction of Reliability, Integrity, and Survivability of Microsystems (PRISM) uncertainty quantification (PUQ) framework was applied. Three uncertainty propagation trials investigate the impact of uncertainty in metal material properties, thermal boundary conditions, and a modeling parameter on outputs of interest, such as fraction liquid at different times in the process cycle and shrinkage porosity volume, in an industrial A380 aluminum alloy HPDC process. This quantification of the output uncertainty establishes the reliability of the simulation results and can inform process design choices, such as the determination of the part ejection time. The results are most sensitive to the uncertainty in the interfacial heat transfer (for both outputs of interest) and the feeding effectivity (FE) (a model parameter controlling porosity formation determination), while the other heat transfer boundary conditions, model parameters, and all the properties play a secondary role in output uncertainty.

Impact of Sweeping Jet on Area-Averaged Impingement Heat Transfer

2019 ◽  
Author(s):  
Andrea Osorio ◽  
Justin Hodges ◽  
Husam Zawati ◽  
Erik J. Fernandez ◽  
Jayanta S. Kapat ◽  
...  
Keyword(s):  
Heat Transfer ◽  
Heated Surface ◽  
Thermal Inertia ◽  
Jet Impingement ◽  
Target Surface ◽  
Bottom Surface ◽  
Fluidic Oscillator ◽  
Surface Temperatures ◽  
Sweeping Motion ◽  
The Impact

Abstract A series of sweeping jet-impingement experiments are conducted over a circular heated surface, with a main objective of understanding the impact of the unique flow field on the resulting heat transfer. The sweeping motion of the fluidic oscillator is influenced by the sweeping frequency and sweeping angle where each is directly dependent on the geometric design (i.e. internal feedback loops, mixing chamber, etc.). The target surface consists of a heated copper disk, where heater power is supplied to the bottom surface of the disk and adjusted until a differential of 30°C is obtained between the jet and target surface temperatures. An energy balance over the target surface temperatures provides a means for calculating area-averaged heat transfer rate, hence Nusselt number. An increase in the sweeping jet’s thermal inertia initiates an augmentation in heat transfer due to sweeping motion of the jet across the target surface. PIV data was acquired for two jet configurations, confined and unconfined, so that the recirculation behavior can be determined. The fluidic oscillator is found to improve only at a low z/d. At large z/d (greater than 4 in this study), the fluidic oscillator adversely affects the heat transfer.

Experimental Study on Behavior of Bubbles and Temperature Fluctuation of Heat Transfer Surface by Using Heat Transfer Surface With Artificial Cavities Created by MEMS Technology

2009 ◽  
Author(s):  
Takato Sato ◽  
Yasuo Koizumi ◽  
Hiroyasu Ohtake
Keyword(s):  
Heat Transfer ◽  
Surface Temperature ◽  
Correlation Coefficients ◽  
Side Surface ◽  
Nucleate Boiling ◽  
Heat Transfer Surface ◽  
Back Side ◽  
Mems Technology ◽  
Standard Deviations ◽  
Thermal Influence

Pool nucleate boiling heat transfer experiments were performed for water using heat transfer surfaces having a unified cavity. A single cylindrical hole of 10 μm in diameter and 40 μm in depth was formed on a mirror-finished silicon wafer of 0.2 mm in thickness using the Micro-Electro Mechanical Systems (MEMS) technology. This silicon plate was used as the heat transfer surface. The back side of the heat transfer surface was heated by a semi-conductor laser beam. The back-side surface temperature was measured by a radiation thermograph with a temperature resolution of 0.08 K and a time resolution of 3 ms/line. Experiments were conducted in the range up to 1.35 × 105 W/m2. The standard deviations of the local fluctuating heat transfer surface temperature were calculated. So the cross-correlation coefficients between the cavity center and a certain point were calculated by using the standard deviations and the time-series surface temperature data. Then, the intensity of the thermal influence exerted by the boiling bubbles on the local position was derived. The thermal influence extents determined from the intensity were 2.1 – 3.3 times larger than the mean diameter of all departure bubbles in the present experimental range.

scholarly journals Large Eddy Simulations with Conjugate Heat Transfer (CHT) modeling of Internal Combustion Engines (ICEs)

2019 ◽  
Vol 74 ◽  
pp. 51 ◽  
Author(s):  
Angela Wu ◽  
Seunghwan Keum ◽  
Volker Sick
Keyword(s):  
Heat Transfer ◽  
Surface Temperature ◽  
Wall Temperature ◽  
Conjugate Heat Transfer ◽  
Internal Combustion Engines ◽  
Internal Combustion ◽  
Large Eddy Simulations ◽  
Temperature Fields ◽  
Large Eddy ◽  
The Impact

In this study, the effects of the thermal boundary conditions at the engine walls on the predictions of Large-Eddy Simulations (LES) of a motored Internal Combustion Engine (ICE) were examined. Two thermal boundary condition cases were simulated. One case used a fixed, uniform wall temperature, which is typically used in conventional LES modeling of ICEs. The second case utilized a Conjugate Heat Transfer (CHT) modeling approach to obtain temporally and spatially varying wall temperature. The CHT approach solves the coupled heat transfer problem between fluid and solid domains. The CHT case included the solid valves, piston, cylinder head, cylinder liner, valve seats, and spark plug geometries. The simulations were validated with measured bulk flow, near-wall flow, surface temperature, and surface heat flux. The LES quality of both simulations was also discussed. The CHT results show substantial spatial, temporal, and cyclic variability of the wall heat transfer. The surface temperature dynamics obtained from the CHT model compared well with measurements during the compression stroke, but the absolute magnitude was 5 K (or 1.4%) off and the prediction of the drop in temperature after top dead center suffered from temporal resolution limitations. Differences in the predicted flow and temperature fields between the uniform surface temperature and CHT simulations show the impact of the surface temperature on bulk behavior.

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