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Energies
Volume 18
Issue 17
10.3390/en18174514
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This is an early access version, the complete PDF, HTML, and XML versions will be available soon.
Article

Integrated Surrogate Model-Based Approach for Aerodynamic Design Optimization of Three-Stage Axial Compressor in Gas Turbine Applications

by
Jinxin Cheng
1,2,†,
Bin Li
3,†,
Xiancheng Song
4,
Xinfang Ji
5,
Yong Zhang
6,
Jiang Chen
3 and
Hang Xiang
3,*
1
School of Mechanical Engineering, University of Science and Technology Beijing, Beijing 100081, China
2
Shunde Innovation School, University of Science and Technology Beijing, Foshan 528300, China
3
School of Energy and Power Engineering, Beihang University, Beijing 100191, China
4
Beijing Institute of Precision Mechatronics and Controls, Beijing 100076, China
5
School of Computer Science and Engineering, North Minzu University, Yinchuan 750030, China
6
School of Computer Science, China University of Mining and Technology, Xuzhou 221008, China
*
Author to whom correspondence should be addressed.
†
These authors contributed equally to this work.
Energies 2025, 18(17), 4514; https://doi.org/10.3390/en18174514 (registering DOI)
Submission received: 11 July 2025 / Revised: 13 August 2025 / Accepted: 22 August 2025 / Published: 25 August 2025
(This article belongs to the Special Issue Advanced Methods for the Design and Optimization of Turbomachinery)
Versions Notes

Abstract

The refined aerodynamic design optimization of multistage compressors is a typical high-dimensional and expensive optimization problem. This study proposes an integrated surrogate model-assisted evolutionary algorithm combined with a Directly Manipulated Free-Form Deformation (DFFD)-based parametric dimensionality reduction method, establishing a high-precision and efficient global parallel aerodynamic optimization platform for multistage axial compressors. The DFFD method achieves a balance between flexibility and low-dimensional characteristics by directly controlling the surface points of blades, which demonstrates a particular suitability for the aerodynamic design optimization of multistage axial compressors. The integrated surrogate model enhances prediction accuracy by simultaneously identifying optimal solutions and the most uncertain solutions, effectively addressing highly nonlinear design space challenges. A three-stage axial compressor in a heavy-duty gas turbine is selected as the optimization object. The results demonstrate that the optimization task takes less than 48 h and achieves an improvement of 0.6% and 4% in the adiabatic efficiency and surge margin, respectively, while maintaining a nearly unchanged flow rate and pressure ratio at the design point. The proposed approach provides an efficient and reliable solution for complex aerodynamic optimization problems.
Keywords: axial compressor; aerodynamic design optimization; directly manipulated free-form deformation; prescreening surrogate model; differential evolutionary algorithm axial compressor; aerodynamic design optimization; directly manipulated free-form deformation; prescreening surrogate model; differential evolutionary algorithm

Share and Cite

MDPI and ACS Style

Cheng, J.; Li, B.; Song, X.; Ji, X.; Zhang, Y.; Chen, J.; Xiang, H. Integrated Surrogate Model-Based Approach for Aerodynamic Design Optimization of Three-Stage Axial Compressor in Gas Turbine Applications. Energies 2025, 18, 4514. https://doi.org/10.3390/en18174514

AMA Style

Cheng J, Li B, Song X, Ji X, Zhang Y, Chen J, Xiang H. Integrated Surrogate Model-Based Approach for Aerodynamic Design Optimization of Three-Stage Axial Compressor in Gas Turbine Applications. Energies. 2025; 18(17):4514. https://doi.org/10.3390/en18174514

Chicago/Turabian Style

Cheng, Jinxin, Bin Li, Xiancheng Song, Xinfang Ji, Yong Zhang, Jiang Chen, and Hang Xiang. 2025. "Integrated Surrogate Model-Based Approach for Aerodynamic Design Optimization of Three-Stage Axial Compressor in Gas Turbine Applications" Energies 18, no. 17: 4514. https://doi.org/10.3390/en18174514

APA Style

Cheng, J., Li, B., Song, X., Ji, X., Zhang, Y., Chen, J., & Xiang, H. (2025). Integrated Surrogate Model-Based Approach for Aerodynamic Design Optimization of Three-Stage Axial Compressor in Gas Turbine Applications. Energies, 18(17), 4514. https://doi.org/10.3390/en18174514

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