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Research Papers

J. Turbomach. 2017;140(3):031001-031001-10. doi:10.1115/1.4038468.

The aspect of hub cavity purge has been investigated in a high-pressure axial low-reaction turbine stage. The cavity purge is an important part of the secondary air system, used to isolate the cavities below the hub level from the hot main annulus flow. A full-scale cold-flow experimental rig featuring a rotating stage was used in the investigation, quantifying main annulus flow field impact with respect to purge flow rate as it was injected upstream of the rotor. Five operating speeds were investigated of which three with respect to purge flow, namely, a high loading design case, and two high-speed points encompassing the peak efficiency. At each of these operating speeds, the amount of purge flow was varied from 0% to 2%. Observing the effect of the purge rate on measurement plane averaged parameters, a minor flow angle decrease and Mach number increase is seen for the low speed case, while maintaining near constant values for the higher operating speeds. The prominent effect due to purge is seen in the efficiency, showing a linear sensitivity to purge of 1.3%-points for every 1% of added purge flow for the investigated speeds. While spatial average values of flow angle and Mach number are essentially unaffected by purge injection, important spanwise variations are observed and highlighted. The secondary flow structure is strengthened in the hub region, leading to a generally increased over-turning and lowered flow velocity. Meanwhile, the added volume flow through the rotor leads to higher outlet flow velocities visible at higher span, with associated decreased turning. A radial efficiency distribution is utilized, showing negative impact through span heights from 15% to 70%. Pitchwise variation of investigated flow parameters is significantly influenced by purge flow, making this a parameter to include for instance when evaluating benefits of stator clocking positions.

Commentary by Dr. Valentin Fuster
J. Turbomach. 2017;140(3):031002-031002-9. doi:10.1115/1.4038411.

The present study aims at characterizing the flow field and heat transfer for a schematic but realistic vane cooling scheme. Experimentally, both velocity and heat transfer measurements are conducted to provide a detailed database of the investigated configuration. From a numerical point of view, the configuration is investigated using isotropic and anisotropic Reynolds-averaged Navier–Stokes (RANS) turbulence models. A hybrid RANS/large eddy simulation (LES) technique is also considered to evaluate potential unsteady effects. Both experimental and numerical results show a very complex three-dimensional (3D) flow. Air is not evenly distributed between different injections, mainly because of a large recirculation flow. Due to the strong flow deviation at the hole inlet, the velocity distribution and the turbulence characteristics at the hole exit are far from fully developed profiles. The comparison between particle image velocimetry (PIV) measurements and numerical results shows a reasonable agreement. However, coming to heat transfer, all RANS models exhibit a major overestimation compared to IR thermography measurements. The Billard–Laurence model does not bring any improvement compared to a classical k–ω shear stress transport (SST) model. The hybrid RANS/LES simulation provides the best heat transfer estimation, exhibiting potential unsteady effects ignored by RANS models. Those conclusions are different from the ones usually obtained for a single fully developed impinging jet.

Commentary by Dr. Valentin Fuster
J. Turbomach. 2017;140(3):031003-031003-9. doi:10.1115/1.4038413.

Improvements in turbine design methods have resulted in the development of blade profiles with both high lift and good Reynolds lapse characteristics. An increase in aerodynamic loading of blades in the low-pressure turbine (LPT) section of aircraft gas turbine engines has the potential to reduce engine weight or increase power extraction. Increased blade loading means larger pressure gradients and increased secondary losses near the endwall. Prior work has emphasized the importance of reducing these losses if highly loaded blades are to be utilized. The present study analyzes the secondary flow field of the front-loaded low-pressure turbine blade designated L2F with and without blade profile contouring at the junction of the blade and endwall. The current work explores the loss production mechanisms inside the LPT cascade. Stereoscopic particle image velocimetry (SPIV) data and total pressure loss data are used to describe the secondary flow field. The flow is analyzed in terms of total pressure loss, vorticity, Q-Criterion, turbulent kinetic energy, and turbulence production. The flow description is then expanded upon using an implicit large eddy simulation (ILES) of the flow field. The Reynolds-averaged Navier–Stokes (RANS) momentum equations contain terms with pressure derivatives. With some manipulation, these equations can be rearranged to form an equation for the change in total pressure along a streamline as a function of velocity only. After simplifying for the flow field in question, the equation can be interpreted as the total pressure transport along a streamline. A comparison of the total pressure transport calculated from the velocity components and the total pressure loss is presented and discussed. Peak values of total pressure transport overlap peak values of total pressure loss through and downstream of the passage suggesting that the total pressure transport is a useful tool for localizing and predicting loss origins and loss development using velocity data which can be obtained nonintrusively.

Commentary by Dr. Valentin Fuster
J. Turbomach. 2017;140(3):031004-031004-13. doi:10.1115/1.4038403.

The application of a new computational capability for accurate and efficient high-fidelity scale-resolving simulations of turbomachinery is presented. The focus is on the prediction of heat transfer and boundary layer characteristics with comparisons to the experiments of Arts et al. (1990, “Aero–Thermal Investigation of a Highly Loaded Transonic Linear Turbine Guide Vane Cascade,” von Karman Institute for Fluid Dynamics, Rhode St. Genese, Belgium, Technical Note No. 174.) for an uncooled, transonic, linear high-pressure turbine (HPT) inlet guide vane cascade that includes the effects of elevated inflow turbulence. The computational capability is based on an entropy-stable, discontinuous Galerkin (DG) spectral element approach that extends to arbitrarily high orders of spatial and temporal accuracy. The suction side of the vane undergoes natural transition for the clean inflow case, while bypass transition mechanisms are observed in the presence of elevated inflow turbulence. The airfoil suction-side boundary layer turbulence characteristics during the transition process thus differ significantly between the two cases. Traditional simulations based on the Reynolds-averaged Navier–Stokes (RANS) fail to predict these transition characteristics. The heat transfer characteristics for the simulations with clean inflow agree well with the experimental data, while the heat transfer characteristics for the bypass transition cases agree well with the experiment when higher inflow turbulence levels are prescribed. The differences between the clean and inflow turbulence cases are also highlighted through a detailed examination of the characteristics of the transitional and turbulent flow fields.

Commentary by Dr. Valentin Fuster
J. Turbomach. 2017;140(3):031005-031005-10. doi:10.1115/1.4038319.

Since the early work on axial compressors, the penalties due to radial clearances between blades and side walls are known and are an ongoing focus of research work. The periodic unsteadiness of the tip clearance vortex (TCV), due to its interaction with the stator wakes, has only rarely been addressed in research papers so far. The current work presents experimental and numerical results from a four-stage low-speed research compressor (LSRC) modeling a state-of-the-art compressor design. Time-resolved experimental measurements have been carried out at three different rotor tip clearances (gap to tip chord: 1.5%, 2.2%, 3.7%) to cover the third rotor's casing static pressure and exit flow field. These results are compared with either steady simulations using different turbulence models or harmonic Reynolds-averaged Navier–Stokes (RANS) calculations to discuss the periodical unsteady TCV development at different clearance heights. The prediction of the local tip leakage flow is clearly improved by the explicit algebraic Reynolds stress model (EARSM) turbulence model compared to the standard shear stress transport (SST) model. The harmonic RANS calculations (using the SST model) improve the prediction of time-averaged pressure rise and are used to analyze the rotor stator interaction in detail. The interaction of the rotor tip flow field with the passing stator wakes causes a segmentation of the TCV and results in a sinusoidal variation in blockage downstream the rotor row.

Commentary by Dr. Valentin Fuster
J. Turbomach. 2017;140(3):031006-031006-11. doi:10.1115/1.4038519.

This paper is the second part of a two-part paper that presents a comprehensive study of the higher-order mode (HOM) mistuned forced response of an embedded rotor blisk in a multistage axial research compressor. The resonant response of the second-stage rotor (R2) in its first chordwise bending (1CWB) mode due to the second harmonic of the periodic passing of its neighboring stators (S1 and S2) is investigated computationally and experimentally at three steady loading conditions in the Purdue three-stage compressor research facility. A nonintrusive stress measurement system (NSMS, or blade tip-timing) is used to measure the blade vibration. Two reduced-order mistuning models of different levels of fidelity are used, namely, the fundamental mistuning model (FMM) and the component mode mistuning (CMM), to predict the response. Although several modes in the 1CWB modal family appear in frequency veering and high modal density regions, they do not heavily participate in the response such that very similar results are produced by the FMM and the CMM models of different sizes. A significant response amplification factor of 1.5–2.0 is both measured and predicted, which is on the same order of magnitude of what was commonly reported for low-frequency modes. In this study, a good agreement between predictions and measurements is achieved for the deterministic analysis. This is complemented by a sensitivity analysis which shows that the mistuned system is highly sensitive to the discrepancies in the experimentally determined blade frequency mistuning.

Commentary by Dr. Valentin Fuster
J. Turbomach. 2017;140(3):031007-031007-11. doi:10.1115/1.4038614.

Cooling of turbine hot-gas-path components can increase engine efficiency, reduce emissions, and extend engine life. As cooling technologies evolved, numerous blade cooling geometries have been and continue to be proposed by researchers and engine builders for internal and external blade and vane cooling. However, the impact of these improved cooling configurations on overall engine performance is the ultimate metric. There is no assurance that obtaining higher cooling performance for an individual cooling technique will result in better turbine performance because of the introduction of additional second law losses, e.g., exergy loss from blade heat transfer, cooling air friction losses, and fluid mixing, and thus, the higher cooling performance might not always be the best solution to improve efficiency. To quantify the effect of different internal and external blade cooling techniques and their combinations on engine performance, a cooled engine model has been developed for industrial gas turbines and aero-engines using MATLAB Simulink. The model has the flexibility to be used for both engine types and consists of uncooled on-design, turbomachinery design, and a cooled off-design analysis in order to evaluate the engine performance parameters by using operating conditions, polytropic efficiencies, material information, and cooling system information. The cooling analysis algorithm involves a second law analysis to calculate losses from the cooling technique applied. The effects of variations in engine parameters such as turbine inlet temperature, by-pass ratio, and operating temperature are studied. The impact of variations in metal Biot number, thermal barrier coating (TBC) Biot number, film cooling effectiveness, internal cooling effectiveness, and maximum allowable blade temperature on engine performance parameters are analyzed. Possible design recommendations based on these variations, and direction of use of this tool for new cooling design validation, are presented.

Commentary by Dr. Valentin Fuster
J. Turbomach. 2017;140(3):031008-031008-12. doi:10.1115/1.4038337.

A high speed 1–1/2 axial compressor stage is simulated in this paper using an unsteady Reynolds-averaged Navier–Stokes (URANS) solver for a full-annulus configuration to capture its nonsynchronous vibration (NSV) flow excitation with rigid blades. A third-order weighted essentially nonoscillatory scheme for the inviscid flux and a second-order central differencing for the viscous terms are used to resolve nonlinear unsteady fluid flows. A fully conservative rotor/stator sliding boundary condition (BC) is employed with multiple-processor capability for rotor/stator sliding interface that accurately captures unsteady wake propagation between the rotor and stator blades while conserving fluxes across the rotor/stator interfaces. The predicted dominant frequencies using the blade tip response signals are not harmonic to the engine order, which is the NSV excitation. The simulation is based on a rotor blade with a 1.1% tip-chord clearance. Comparison with the previous 1/7 annulus simulations show that the time-shifted phase-lag BCs used in the 1/7 annulus are accurate. For most of the blades, the NSV excitation frequency is 6.2% lower than the measurement in the rig test, although some blades displayed slightly different NSV excitation frequencies. The simulation confirms that the NSV is a full annulus phenomenon. The instability of the circumferential traveling vortices in the vicinity of the rotor tip due to the strong interaction of incoming flow is the main cause of the NSV excitation. This instability is present in all blades of the rotor annulus. For circumferentially averaged parameters like total pressure ratio, NSV is observed to have an effect on the radial profile, particularly at radial locations above 70% span. A design with a lower loading of the upper blade span and a higher loading of the midblade spans is recommended to mitigate or remove NSV.

Commentary by Dr. Valentin Fuster
J. Turbomach. 2017;140(3):031009-031009-13. doi:10.1115/1.4038690.

A companion experimental and numerical study was conducted for the performance of a row of five sweeping jet (SJ) film cooling holes consisting of conventional curved fluidic oscillators with an aspect ratio (AR) of unity and a hole spacing of P/D = 8.5. Adiabatic film effectiveness (η), thermal field (θ), convective heat transfer coefficient (h), and discharge coefficient (CD) were measured at two different freestream turbulence levels (Tu = 0.4% and 10.1%) and four blowing ratios (M = 0.98, 1.97, 2.94, and 3.96) at a density ratio of 1.04 and hole Reynolds number of ReD = 2800. Adiabatic film effectiveness and thermal field data were also acquired for a baseline 777-shaped hole. The SJ film cooling hole showed significant improvement in cooling effectiveness in the lateral direction due to the sweeping action of the fluidic oscillator. An unsteady Reynolds-averaged Navier–Stokes (URANS) simulation was performed to evaluate the flow field at the exit of the hole. Time-resolved flow fields revealed two alternating streamwise vortices at all blowing ratios. The sense of rotation of these alternating vortices is opposite to the traditional counter-rotating vortex pair (CRVP) found in a “jet in crossflow” and serves to spread the film coolant laterally.

Commentary by Dr. Valentin Fuster
J. Turbomach. 2017;140(3):031010-031010-11. doi:10.1115/1.4038711.

The present study aims to understand the flow, turbulence, and heat transfer in a single row narrow impingement channel for gas turbine heat transfer applications. Since the advent of several advanced manufacturing techniques, narrow wall cooling schemes have become more practical. In this study, the Reynolds number based on jet diameter was 15,000, with the jet plate having fixed jet hole diameters and hole spacing. The height of the channel is three times the impingement jet diameter. The channel width is four times the jet diameter of the impingement hole. The dynamics of flow and heat transfer in a single row narrow impingement channel are experimentally and numerically investigated. Particle image velocimetry (PIV) was used to reveal the detailed information of flow phenomena. PIV measurements were taken at a plane normal to the target wall along the jet centerline. The mean velocity field and the turbulent statistics generated from the mean flow field were analyzed. The experimental data from the PIV reveal that the flow is highly anisotropic in a narrow impingement channel. To support experimental data, wall-modeled large eddy simulation (LES) and Reynolds-averaged Navier–Stokes (RANS) simulations (shear stress transport k–ω, ν2−f, and Reynolds stress model (RSM)) were performed in the same channel geometry. Mean velocities calculated from the RANS and LES were compared with the PIV data. Turbulent kinetic energy budgets were calculated from the experiment, and were compared with the LES and RSM model, highlighting the major shortcomings of RANS models to predict correct heat transfer behavior for the impingement problem. Temperature-sensitive paint (TSP) was also used to experimentally obtain a local heat transfer distribution at the target and the side walls. An attempt was made to connect the complex aerodynamic flow behavior with the results obtained from heat transfer, indicating heat transfer is a manifestation of flow phenomena. The accuracy of LES in predicting the mean flow field, turbulent statistics, and heat transfer is shown in the current work as it is validated against the experimental data through PIV and TSP.

Commentary by Dr. Valentin Fuster

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