Reduced Rough-Surface Parameterization for Use With the Discrete-Element Model

The discrete-element model for flows over rough surfaces was recently modified to predict drag and heat transfer for flow over randomly-rough surfaces. However, the current form of the discrete-element model requires a blockage fraction and a roughness-element diameter distribution as a function of height to predict the drag and heat transfer of flow over a randomly-rough surface. The requirement for a roughness element-diameter distribution at each height from the reference elevation has hindered the usefulness of the discrete-element model and inhibited its incorporation into a computational fluid dynamics (CFD) solver. To incorporate the discrete-element model into a CFD solver and to enable the discrete-element model to become a more useful engineering tool, the randomly-rough surface characterization must be simplified. Methods for determining characteristic diameters for drag and heat transfer using complete three-dimensional surface measurements are presented. Drag and heat transfer predictions made using the model simplifications are compared to predictions made using the complete surface characterization and to experimental measurements for two randomly-rough surfaces. Methods to use statistical surface information, as opposed to the complete three-dimensional surface measurements, to evaluate the characteristic dimensions of the roughness are also explored.

Effect of Temperature Ratio on Jet Array Impingement Heat Transfer

Considered are the effects of temperature ratio on the heat transfer from an array of jets impinging on a flat plate. At constant Reynolds number of 18000, and constant Mach number of 0.2, different ratios of target plate temperature to jet temperature are employed. The spacing between holes in the streamwise direction X is 8D, and the spanwise spacing between holes in a given streamwise row Y is also 8D. The target plate is located 3D away from the impingement hole exits. Experimental results show that local, line-averaged, and spatially-averaged Nusselt numbers decrease as the Tw/Tj temperature ratio increases. This is believed to be due to the effects of temperature-dependent fluid properties, as they affect local and global turbulent transport in the flow field created by the array of impinging jets. The effect of temperature ratio on crossflow-to-jet mass velocity ratio and discharge coefficients are also examined.

Film Cooling Effectiveness on a Rotating Turbine Platform Using Pressure Sensitive Paint Technique

Film cooling effectiveness is measured on a rotating turbine blade platform for coolant injection through discrete holes using pressure sensitive paint technique (PSP). Most of the existing literatures provide information only for stationary end-walls. The effects of rotation on the platform film cooling effectiveness are not well documented. Hence, the existing 3-stage turbine research facility at TPFL, Texas A&M University was re-designed and installed to enable coolant gas injection on the 1st stage rotor platform. Two distinct coolant supply loops were incorporated into the rotor to facilitate separate feeds for upstream cooling using stator-rotor gap purge flow and downstream discrete-hole film cooling. As a continuation of the previously published work involving stator-rotor gap purge cooling, this study investigates film cooling effectiveness on the 1st stage rotor platform due to coolant gas injection through nine discrete holes located downstream within the passage region. Film cooling effectiveness is measured for turbine rotor frequencies of 2400rpm, 2550rpm and 3000rpm corresponding to rotation numbers of Ro = 0.18, 0.19 and 0.23 respectively. For each of the turbine rotational frequencies, film cooling effectiveness is determined for average film-hole blowing ratios of Mholes = 0.5, 0.75, 1.0, 1.25, 1.5 and 2.0. To provide a complete picture of hub cooling under rotating conditions, simultaneous injection of coolant gas through upstream stator-rotor purge gap and downstream discrete film-hole is also studied. The combined tests are conducted for gap purge flow corresponding to coolant to mainstream mass flow ratio of MFR = 1% with three downstream film-hole blowing ratios of Mholes = 0.75, 1.0 and 1.25 for each of the three turbine speeds. The results for combined upstream stator-rotor gap purge flow and downstream discrete holes provide information about the optimum purge flow coolant mass, average coolant hole blowing ratios for each rotational speed and coolant injection location along the passage to obtain efficient platform film cooling.

Characterisation of Static Strip Seal Flow

Strip seals are used in gas turbine engines between two static elements or between components which do not move relative to each other, such as Nozzle Guide Vanes (NGVs). The key role of a strip seal between NGV segments is sealing between the flow through the main stream annulus and the internal air system, a further purpose is to limit the inter-segmental movements. In general the shape of the strip seal is a rectangular strip that fits into two slots in adjacent components. The minimum clearance required for static strip seals must be found by accounting for thermal expansion, misalignment, and application, to allow correct fitment of the strip seals. Any increase in leakage raises the cost due to an increase in the cooling air use, which is linked to specific fuel consumption, and it can also alter gas flow paths and performance. The narrow path within the seal assembly, especially the height has the most significant affect on leakage. The height range of the narrow path studied in this paper is 0.01–0.06 mm. The behaviour of the flow passing through the narrow path has been studied using CFD modelling and measurements in a bespoke rig. The CFD and experimental results show that normalized leakage flow increases with pressure ratio before reaching a maximum. The main aim of this paper is to provide new experimental data to verify the CFD modelling for static strip seals. The typical flow characteristics validated by CFD modelling and experiments can be used to predict the flow behaviour for future static strip seal designs.

Endwall Heat Transfer Measurements in a Staggered Pin Fin Array With an Adiabatic Pin

Full surface endwall heat transfer distributions have been acquired in a staggered pin fin array with the use of an infrared camera. Values are presented at Reynolds numbers of 3000, 10,000 and 30,000 based on pin diameter and average velocity through adjacent pins. Average endwall Nusselt numbers agree closely with archival values at each Reynolds number. Locally averaged heat transfer levels show a substantial increase from the inlet through the first few rows and finally a nearly streamwise periodic condition in the second half of the eight row geometry. Increasing levels of heat transfer in the inlet region can be attributed to the leading edge vortex system, flow acceleration around pins, and the generation of turbulence. Distributions of turbulence intensity and turbulent scale are shown to help document the turbulent transport conditions through the array. Detailed endwall Nusselt number distributions are presented and compared at the three Reynolds numbers for the first four and last four rows. These detailed heat transfer distributions highlight the influence of the horseshoe vortex system in the entrance region and the wake generated turbulence throughout the pin fin array. Local velocity and turbulence distributions are presented together with local Stanton number and skin friction coefficient data to examine the aggressive nature of the turbulent mixing.

An Investigation of Tip Force Characteristics of Brush Seals

Thanks to their compliant nature and superior leakage performance over conventional labyrinth seals, brush seals found increasing use in turbomachinery. Utilizing high temperature super-alloy fibers and their compliance capability these seals maintain contact with the rotor for a wide range of operating conditions leaving minimal passage for parasitic leakage flow. Consequently, the contact force/pressure generated at seal rotor interface is of importance for sustained seal performance and longevity of its service life. Although some analytical and numerical models have been developed to estimate bristle tip pressures, they simply rely on linear beam equation calculations and other such assumptions for loading cases. In this paper, previously available analytical and/or numerical models for bristle tip force/pressure have been modified and enhanced. The nonlinear cantilever beam equation has been solved and results are compared to a linear cantilever beam equation solution to establish application boundaries for both methods. The results are also compared to experimental data. With the support of testing, an empirical model has been developed for tip forces under operating conditions.

Heat Transfer From Low Aspect Ratio Pin Fins

The performance of many engineering devices from power electronics to gas turbines is limited by thermal management. Heat transfer augmentation in internal flows is commonly achieved through the use of pin fins, which increase both surface area and turbulence. The present research is focused on internal cooling of turbine airfoils using a single row of circular pin fins that is oriented perpendicular to the flow. Low aspect ratio pin fins were studied whereby the channel height to pin diameter was unity. A number of spanwise spacings were investigated for a Reynolds number range between 5000 to 30,000. Both pressure drop and spatially-resolved heat transfer measurements were taken. The heat transfer measurements were made on the endwall of the pin fin array using infrared thermography and on the pin surface using discrete thermocouples. The results show that the heat transfer augmentation relative to open channel flow is the highest for smallest spanwise spacings and lowest Reynolds numbers. The results also indicate that the pin fin heat transfer is higher than the endwall heat transfer.

Numerical Modeling of Heat Transfer and Pressure Losses for Uncooled Gas Turbine Blade Tip: Effect of Tip Clearance and Tip Geometry

A computational study has been performed to predict the heat transfer distribution on the blade tip surface for a representative gas turbine first stage blade. CFD predictions of blade tip heat transfer are compared to test measurements taken in a linear cascade, when available. The blade geometry has an inlet Mach number of 0.3 and an exit Mach number of 0.75, pressure ratio of 1.5, exit Reynolds number based on axial chord of 2.57×106, and total turning of 110 deg. Three blade tip configurations were considered; they are flat tip, a full perimeter squealer, and an offset squealer where the rim is offset to the interior of the tip perimeter. These three tip geometries were modeled at three tip clearances of 1.25, 2.0, and 2.75% of blade span. The tip heat transfer results of the numerical models agree fairly well with the data and are comparable to other CFD predictions in the open literature.

Experimental Studies on Cooling Effectiveness of the Double-Decker Air Jet Impingement With Film Outflow

Experiments were carried out to investigate the cooling effectiveness of a lamellar double-decker impingement/effusion structure. Infrared radiation (I.R.) thermal camera was used to measure the temperature on the outside surface of the lamellar double-decker. Experimental results were obtained for a wide range of governing parameters (blowing rate M (0.0017∼0.0066), the ratio of the jet impingement distance to the diameter of film hole H/D (0.5∼1.25), the ratio of the distance between the jet hole and film hole to the diameter of the film hole P/D (0, 3, 4), and the material of double-decker (Steel and Copper)). It was observed that the local cooling effectiveness η varies with all these parameters in a complicated way. All the results show that higher cooling effectiveness η is achieved in larger blowing rate cases. A certain range of H/D and P/D can be designed to result in the maximum cooling effectiveness η. And η is less sensitive to the material type compared with those parameters such as H/D, M and P/D.

Measurement and Analysis of Aerodynamic and Thermodynamic Losses in Pre-Swirl System Arrangements

In order to separately describe the dominating loss mechanisms in pre-swirled cooling air delivery systems, discharge, temperature and velocity measurements were performed for numerous designs. Whereas pre-swirl nozzles, as first component, were characterized by their discharge coefficients, total pressure losses occurring at the inlet of the receiver holes were correlated depending on the incident angle of the cooling flow. To quantify losses generated inside the rotor-stator gap, flow velocity data, acquired by means of 3D PIV, were compared to total temperature measurements. In addition the influence of wall friction and mixing losses due to the strong velocity gradients inside the preswirl chamber was discussed by means of a simple loss model. Finally, dimensionless loss coefficients, discharge behaviour and expected cooling temperature can be predicted for a family of realistic pre-swirl systems. Moreover, this detailed description of the losses provides a methodology to quantify the impact of individual loss sources on the global efficiency of the pre-swirl system, thus allowing improved designs.