Steady Reynolds-averaged Navier--Stokes (RANS) simulations were performed to examine the ability of four turbulence models—realizable k–ε (k–ε), shear-stress transport (SST), Reynolds stress model with linear pressure strain (RSM-LPS), and stress-omega RSM (RSM-τω)—to predict the turbulent flow and heat transfer in a trapezoidal U-duct with and without a staggered array of pin fins. Results generated for the heat-transfer coefficient (HTC) were compared with experimental measurements. For the smooth U-duct, the maximum relative error in the averaged HTC in the up-leg is 2.5% for k–ε, SST, and RSM-τω and 9% for RSM-LPS. In the turn region, the maximum is 50% for k–ε and RSM-LPS, 14.5% for RSM-τω, and 29% for SST. In the down-leg, SST gave the best predictions and RSM-τω being a close second with maximum relative error less than 10%. The ability to predict the separated flow downstream of the turn dominated the performance of the models. For the U-duct with pin fins, SST and RSM-τω predicted the best, and k–ε predicted the least accurate HTCs. For k–ε, the maximum relative error is about 25%, whereas it is 15% for the SST and RSM-τω, and they occur in the turn. In the turn region, the staggered array of pin fins was found to behave like guide vanes in turning the flow. The pin fins also reduced the size of the separated region just after the turn.

A generic impingement cooling system for turbomachinery application is modeled experimentally and numerically to investigate heat transfer and pressure loss characteristics. The experimental setup consists of an array of 9 × 9 jets impinging on a target plate with cubic micro pin fins. The cubic micro pin fins have an edge length of 0.22 D and enlarge the target area by 150%. Experimentally heat transfer is measured by the transient liquid crystal (TLC) method. The transient method used requires a heated jet impinging on a cold target plate. As reference temperature for the heat transfer coefficient, we use the total jet inlet temperature which is measured via thermocouples in the jet center. The computational fluid dynamics (CFD) model was realized within the software package ANSYS CFX. This model uses a Steady-state 3D Reynolds-averaged Navier–Stokes (RANS) approach and the shear stress transport (SST) turbulence model. Boundary conditions are chosen to mimic the experiments as close as possible. The effects of different jet-to-plate spacing (H/D = 3–5), crossflow schemes, and jet Reynolds number (15,000–35,000) are investigated experimentally and numerically. The results include local Nusselt numbers as well as area and line averaged values. Numerical simulations allow a detailed insight into the fluid mechanics of the problem and complement experimental measurements. A good overall agreement of experimental and numerical behavior for all investigated cases could be reached. Depending on the crossflow scheme, the cubic micro pin fin setup increases the heat flux to about 134–142% compared to a flat target plate. At the same time, the Nusselt number slightly decreases. The micro pin fins increase the pressure loss by not more than 14%. The results show that the numerical model predicts the heat transfer characteristics of the cubic micro pin fins in a satisfactory way.

This paper reports endwall film-cooling investigations with single and multiple rows of fan-shaped film holes using temperature-sensitive paint (TSP). The experiments are carried out in a six-bladed linear cascade based on the geometry of a highly loaded gas turbine first vane. The film effectiveness performance of the cooling rows is investigated under the influence of enhanced near-wall secondary flow. Tests are conducted at three different loading conditions changing the profile incidence. Film-cooling injection is established at elevated coolant density ratios of 1.4 using heated carbon dioxide. Due to the finite thermal conductivity of the wall material, the heat conduction effects observed in the measured temperature fields are assessed by a newly developed data analysis based on a finite element thermal analysis and tracking algorithms along CFD-computed near-wall surface streamlines. The results showed that the coolant trajectories are visibly influenced revealing the intense interaction between the film jets and the near-wall flow field. These effects are certainly enhanced with higher incidence leading to increased streamwise coolant consumption and reduced wall coverage. At the cascade inlet, the film-cooling injection is significantly affected by the near-wall flow field showing distinct over- and undercooled regions. Due to the enhanced deflection and mixing of the film jets injected from a single row, area-averaged film effectiveness and wall coverage decreases about 9 and 11%, respectively. With adding more cooling holes to this endwall area, the influence of the enhanced secondary flow becomes more pronounced. Hence, larger reduction in film effectiveness of 23% and wall coverage with 28% is observed. For single row injection at the airfoil pressure side, the stronger secondary flow motion with intensified streamwise mixing leads to a visibly decreased endwall coverage ratio of about 38% and maximum flow path reduction of about 41%. In this case, film effectiveness is found to be reduced up to 47% due to the small amount of coolant injected through this row. This effect is significantly smaller when more cooling rows are added showing an almost constant cooling performance for all incidence cases.