Editor’s Choice Articles

In the coming carbon-neutral era, industrial gas turbines (GT) will continue to play an important role as energy conversion equipment with high thermal efficiency and as stabilizers of the electric power grid. Because of the transition to a clean fuel, such as hydrogen or ammonia, the main modifications will lie with the combustor. It can be expected that small and medium-sized gas turbines will burn fewer inferior fuels, and the scope of cogeneration activities they are used for will be expanded. Industrial gas turbine cycles including CCGT appropriate for the carbon-neutral era are surveyed from the viewpoint of thermodynamics. The use of clean fuels and carbon capture and storage (CCS) will inevitably increase the unit cost of power generation. Therefore, the first objective is to present thermodynamic cycles that fulfil these requirements, as well as their verification tests. One conclusion is that it is necessary to realize the oxy-fuel cycle as a method to utilize carbon-heavy fuels and biomass and not generate NO_x from hydrogen combustion at high temperatures. The second objective of the authors is to show the required morphology of the cooling structures in airfoils, which enable industrial gas turbines with a higher efficiency. In order to achieve this, a survey of the historical development of the existing cooling methods is presented first. CastCool^® and wafer and diffusion bonding blades are discussed as turbine cooling technologies applicable to future GTs. Based on these, new designs already under development are shown. Most of the impetus comes from the development of aviation airfoils, which can be more readily applied to industrial gas turbines because the operation will become more similar. Double-wall cooling (DWC) blades can be considered for these future industrial gas turbines. It will be possible in the near future to fabricate the DWC structures desired by turbine cooling designers using additive manufacturing (AM). Another conclusion is that additively manufactured DWC is the best cooling technique for these future gas turbines. However, at present, research in this field and the data generated are scattered, and it is not yet possible for heat transfer designers to fabricate cooling structures with the desired accuracy. Full article

Predicting pump performance and ensuring operational reliability under two-phase conditions is a major goal of three-dimensional (3D) computational fluid dynamics (CFD) analysis of liquid/gas radial centrifugal pump flows. Hence, 3D CFD methods are increasingly applied to such flows in academia and industry. The CFD analysis of liquid/gas pump flows demands careful selection of sub-models from several fields in CFD, such as two-phase and turbulence modeling, as well as high-quality meshing of complex geometries. This paper presents an overview of current CFD simulation strategies, and recent progress in two-phase modeling is outlined. Particular focus is given to different approaches for dispersed bubbly flow and coherent gas accumulations. For dispersed bubbly flow regions, Euler–Euler Two-Fluid models are discussed, including population balance and bubble interaction models. For coherent gas pocket flow, essentially interface-capturing Volume-of-Fluid methods are applied. A hybrid model is suggested, i.e., a combination of an Euler–Euler Two-Fluid model with interface-capturing properties, predicting bubbly flow regimes as well as regimes with coherent gas pockets. The importance of considering scale-resolving turbulence models for highly-unsteady two-phase flow regions is emphasized. Full article

In applications, the acoustics of fans can differ significantly from the measurements of the standalone fan. This is due to disturbed inflow conditions, for example, caused by a heat exchanger upstream of an axial fan. Resolving the complex geometry and dimensions of typical heat exchangers in aeroacoustic scale-resolving simulations leads to a very high computation effort, which is currently not economically feasible. Turbulence reconstruction tools, such as the FRPM, provide the possibility to model the turbulent inflow conditions, thereby avoiding the representation of the heat exchanger in the aeroacoustic simulations. This approach is tested on a benchmark experiment of a ducted fan with an upstream turbulence grid. Full article

The rising number of applications of the organic Rankine cycle (ORC) or supercritical CO₂ (sCO₂) power systems have shaped a new branch of fluid mechanics called non-ideal compressible fluid dynamics (NICFD). This field of fluid mechanics is concerned with flows of vapors or gases, which are characterized by substantial deviations from the perfect gas model. In extreme cases, even non-classical gas dynamic phenomena could occur. Although these non-ideal compressible flows are the subject of sophisticated numerical simulation studies today, there is also a growing need for experimental data for validating purposes. In the last couple of years, new experimental test rigs designed for investigating non-ideal compressible fluid dynamics have been developed and commissioned. Classical practical measurement techniques are currently being re-developed and applied to non-ideal compressible flows. Despite its substantial relevance, information about these measurement techniques and their differences from conventional methods in the open literature is scarce. The present review article is an attempt to reduce that gap. After briefly discussing the thermodynamics and fluid dynamics of non-ideal compressible flows, the currently available test rigs and their utilized measurement techniques are reviewed. This review discusses schlieren optical investigations, pneumatic and laser-optical methods, and hot-wire anemometry for non-ideal compressible flows. Full article

The complex flow conditions in Pelton turbines make it challenging to gain detailed insight into the local flow processes. However, CFD methods offer vast potential for developing and optimising Pelton turbines due to these flow conditions. In a comprehensive examination, a six-nozzle prototype Pelton turbine with 19 buckets has been investigated using 3D CFD simulations. First, the steady simulations of the manifold and the unsteady runner simulation have been performed with a mesh-based, commercial CFD code, whereby a two-equation turbulence model and the homogeneous two-phase model were used. Then, to limit the simulation time, symmetry was applied in the runner simulation, and also a strategic definition of the mesh element size in selected blocks of higher interest. Subsequently, the simulation results were analysed. Based on the first simulation results, the geometry of the distributor was modified in an iterative process to reduce losses and improve the jet shape. For the improvement of the latter, a characteristic number was introduced to quantify the secondary flows upstream of the nozzles, which act negatively on the jet shape. Furthermore, the results of the runner simulation were analysed with special regard to the jet-bucket interaction from the start to the end of the impingement cycle of a particular bucket. Finally, a potential efficiency increase could be derived from the summary. Full article

Air-cooled condensers (ACCs) are commonly found in power plants working with concentrated solar power or in steam power plants operated in regions with limited water availability. In ACCs, the flow of air is driven toward the heat exchangers by axial fans that are characterized by large diameters and operate at very high mass flow rates with a near-zero static pressure rise. Given the overall requirements in steam plants, these fans are subjected to inflow distortions, unstable operations, and are characterized by high noise emissions. Previous studies show that leading edge bumps in the tip region of axial fans can effectively reduce the sound pressure levels without affecting the static efficiency. Nevertheless, the effects of this treatment in terms of flow patterns and heat exchange in the whole ACC system were not investigated. In this work, the effect of leading edge bumps on the flow patterns is analyzed. Two RANS simulations were carried out using OpenFOAM on a simplified model of the air-cooled condenser. The fans are simulated using a frozen rotor approach. Turbulence modeling relies on the RNG k-epsilon model. The fan is characterized by a diameter of 7.3 m and a 333 m³/s volumetric flow rate at the design point. The presence of the heat exchanger is modeled using a porous medium. The comparison between the flow fields clearly exerts that the modified blade is responsible for the redistribution of radial velocities in the rotor region. This drastically reduces the losses related to the installation of the fan in a real configuration. Full article

In this paper, we present the design and optimization of a centrifugal fan with requirements of maximizing the total-to-static pressure rise and total-to-static efficiency at two operating points and the maximum torque provided by the motor power using a 3D inverse design method, a DOE (design of experiment) study, an RSM (response surface model) and a MOGA (multi-objective genetic algorithm). The fan geometry is parametrized using 13 design parameters, and 120 different designs are generated. The fan performances of all the designs at two operating conditions are evaluated through steady-state CFD simulations. The resulting design matrix is used to create an RSM based on the Kriging method and MOGA is used to search the design space using the RSM and find the optimal design. Full article

This study targets determining impellers of impeller-only axial fans with an optimal hub-to-tip ratio for the highest achievable total-to-static efficiency. Differently from other studies, a holistic approach is chosen. Firstly, the complete class of these fans is considered. Secondly, the radial distribution of blade sweep angle, stagger angle, chord length, and camber are varied to adapt the blades to the complex flow in the hub and tip regions. The tool being used is an optimization scheme with three key components: (i) a database created beforehand by Reynolds-averaged Navier–Stokes (RANS)-predicted performance characteristics of 14,000 designs, (ii) an artificial neural network as a metamodel for the fan performance as a function of 26 geometrical parameters, and (iii) an evolutionary algorithm for optimization, performed on the metamodel. Typically, the hub-to-tip ratios for the impellers proposed by the optimization scheme are smaller than those obtained by applying the classic design rules. A second outcome are the shapes of the blades, which are adapted for a minimum exit loss. These shapes deviate substantially from the classic and even the state-of-the-art “swept-only” or “swept with dihedral” designs. The chord length, stagger, and sweep angle are distributed from hub to tip in a complex manner. The inherent reason is that the scheme tries to minimize not only the dynamic exit loss but also frictional losses due to secondary flows in the hub and tip regions, which eventually results in the maximum achievable total-to-static efficiency. Upon request, the authors will provide the full geometry of the four impellers analysed in some detail in this study to any individual for experimental validation or further analysis of their performance. Full article

The correct computation of flows over rough surfaces in technical systems, such as in turbomachines, is a significant issue for proper simulations of their performance data. Once the flow over rough surfaces is adequately computed in these machines, simulations become more trustworthy and can replace experimental prototyping. Roughness modelling approaches are often implemented in a solver to account for roughness effects in flow simulations. In these approaches, the equivalent sand roughness $k_s$ must be defined as a characteristic parameter of the rough surface. However, it is difficult to determine the corresponding $k_s$-value for a surface roughness. In this context, this paper shows a novel and time-efficient numerical method, the discrete porosity method (DPM), which can be used to determine the $k_s$-value of a rough surface. Applying this method, channel flow simulations were performed with an irregularly distributed cast iron surface from a turbopumps volute. After identifying the fully rough regime, the equivalent sand roughness was determined and a match with $k_s$-values from literature data was found. Subsequently, the established $k_s$-value for cast iron was used in a turbopump simulation with rough walls. The performance data of the pump were validated by experiments and a good agreement between the experimental and simulated performance data was found. Full article

The efficiency definition allows us to compare two machines with each other. In general, the efficiency is defined as the ratio of usable power to the required power. This raises the question: what is the usable power? Most engineers discuss efficiency on the basis of the energy balance, i.e., the first law of thermodynamics. In this paper, we derive the exegetic efficiency taking the second law of thermodynamics into account. Exergy analysis takes into account work and heat and is able to model reality very accurately. On this basis, a comparison between the isentropic and exergetic efficiencies is given. A high-pressure radial fan is used as an example, and the differences are discussed. Therefore, measurements of a non-adiabatic fan are evaluated, and the role of the heat flux in the environment is discussed. The investigations show that a relevant difference between the isentropic and exergetic efficiencies becomes apparent in the partial-load range with high-pressure build-up. The thermal energy contained in the flow belongs proportionally to the exergy, i.e., the working capacity of the gas relative to its environment. For a standard such as ISO 5801 “Fans—Performance testing using standardized airways”, the efficiency must not only be physically correct, it must also be simple and practical. Against this background, the outlook of this paper discusses when and which efficiency definition is appropriate and best suited for a standard. Full article

Data analysis is an important part of aero engine health management. In order to complete accurate condition monitoring, it is necessary to establish more effective analysis tools. Therefore, an integrated algorithm library dedicated for engine anomaly detection is established, which is PyPEFD (Python Package for Engine Fault Detection). Different algorithms for baseline modeling, anomaly detection and trend analysis are presented and compared. In this paper, the simulation data are used to verify the function of the anomaly detection algorithms, successfully completing the detection of multiple faults and comparing the accuracy algorithm under different conditions. Full article

A novel active turbulence grid of the Institute of Fluid Mechanics at FAU Erlangen-Nuremberg is introduced. The focus of this grid is not on basic investigations of fluid mechanics, as is usually the case with active turbulence grids, but the generation of defined inflow conditions for axial fans. Thus, by means of the active turbulence grid, individual turbulence characteristics in the flow to the fan can be changed; therefore, fundamental interactions between the flow mechanics at the axial fan and the sound radiation can be analyzed. In addition, the replication of the flow fields of heat exchangers by the active turbulence grid is the focus of the investigations. The investigations showed that it is possible to use the active turbulence grid to generate defined inflow conditions for axial fans. It was also possible to reproduce the heat exchanger flow fields both for the mean turbulence values and for the spatial distributions. It was found that the grid induces tonal components due to the drive motors, but also that the inherent noise has no significant influence on the spectrum of the fans under investigation. Based on selected turbulence characteristics, direct correlations were found between the spatial distribution of the turbulence level and sound radiation at the first blade passing frequency of the axial fan. As the variance of the turbulence level increases, the sound radiation of the tonal components becomes more pronounced. The total sound pressure level, however, is mainly determined by the low-frequency broadband sound. A linear relationship between the spatial mean value of the turbulence level and the total sound pressure level was found for the investigated axial fan. Full article

Optimization methods have been widely applied to the aerodynamic design of gas turbine blades. While applying optimization to high-fidelity computational fluid dynamics (CFD) simulations has proven capable of improving engineering design performance, a challenge has been overcoming the prolonged run-time due to the computationally expensive CFD runs. Reduced-order models and, more recently, machine learning methods have been increasingly used in gas turbine studies to predict performance metrics and operational characteristics, model turbulence, and optimize designs. The application of machine learning methods allows for utilizing existing knowledge and datasets from different sources, such as previous experiments, CFD, low-fidelity simulations, 1D or system-level studies. The present study investigates inserting a machine learning model that utilizes such data into a high-fidelity CFD driven optimization process, and hence effectively reduces the number of required evaluations of the CFD model. Artificial Neural Network (ANN) models were trained on data from over three thousand two-dimensional (2D) CFD analyses of turbine blade cross-sections. The trained ANN models were then used as surrogates in a nested optimization process alongside a full three-dimensional Navier–Stokes CFD simulation. The much lower evaluation cost of the ANN model allows for tens of thousands of design evaluations to guide the search of the best blade profiles to be used in the more expensive, high-fidelity CFD runs, improving the progress of the optimization while reducing the required computation time. It is estimated that the current workflow achieves a five-fold reduction in computational time in comparison to an optimization process that is based on three-dimensional (3D) CFD simulations alone. The methodology is demonstrated on the NASA/General Electric Energy Efficient Engine (E3) high pressure turbine blade and found Pareto front designs with improved blade efficiency and power over the baseline. Quantitative analysis of the optimization data reveals that some design parameters in the present study are more influential than others, such as the lean angle and tip scaling factor. Examining the optimized designs also provides insight into the physics, showing that the optimized designs have a lower amount of pressure drop near the trailing edge, but have an earlier onset of pressure drop on the suction side surface when compared to the baseline design, contributing to the observed improvements in efficiency and power. Full article

The application of composite fans enables disruptive design possibilities but increases sensitivity to multi-physical resonance between aerodynamic, structure dynamic and acoustic phenomena. As a result, aeroelastic problems increasingly set the stability limit. Test cases of representative geometries without industrial restrictions are a key element of an open scientific culture but are currently non-existent in the turbomachinery community. In order to provide a multi-physical validation benchmark representative of near-future UHBR fan concepts, the open-test-case fan stage ECL5 was developed at Ecole Centrale de Lyon. The design intention was to develop a geometry with high efficiency and a wide stability range that can be realized using carbon fibre composites. This publication aims to introduce the final test case, which is currently fabricated and will be experimentally tested. The fan blades are composed of a laminate made of unidirectional carbon fibres and epoxy composite plies. Their structural properties and the ply orientations are presented. To characterize the test case, details are given on the aerodynamic design of the whole stage, structure dynamics of the fan and aeroelastic stability of the fan. These are obtained with a state-of-art industrial design process: static and modal FEM, RANS and LRANS simulations. Aerodynamic analysis focuses on performance and shows critical flow structures such as tip leakage flow, radial flow migration and flow separations. Mechanical modes of the fan are described and discussed in the context of aeroelastic interactions. Their frequency distribution is validated in terms of resonance risk with respect to synchronous vibration. The aeroelastic stability of the fan is evaluated at representative operating points with a systematic approach. Potential instabilities are observed far from the operating line and do not compromise experimental campaigns. Full article

Computational Fluid Dynamics is one of the most relied upon tools in the design and analysis of components in turbomachines. From the propulsion fan at the inlet, through the compressor and combustion sections, to the turbines at the outlet, CFD is used to perform fluid flow and heat transfer analyses to help designers extract the highest performance out of each component. In some cases, such as the design point performance of the axial compressor, current methods are capable of delivering good predictive accuracy. However, many areas require improved methods to give reliable predictions in order for the relevant design spaces to be further explored with confidence. This paper illustrates recent developments in CFD for turbomachinery which make use of machine learning techniques to augment prediction accuracy, speed up prediction times, analyse and manage uncertainty and reconcile simulations with available data. Such techniques facilitate faster and more robust searches of the design space, with or without the help of optimization methods, and enable innovative designs which keep pace with the demand for improved efficiency and sustainability as well as parts and asset operation cost reduction. Full article

In numerous turbomachinery applications, e.g., in aero-engines with regenerators for improving specific fuel consumption (SFC), heat exchangers with low-pressure loss are required. Pil low-plate heat exchangers (PPHE) are a novel exchanger type and promising candidates for high-speed flow applications due to their smooth profiles avoiding blunt obstacles in the flow path. This work deals with the overall system behavior and gas dynamics of pillow-plate channels. A pillow-plate channel was placed in the test section of a blow-down wind tunnel working with dry air, and compressible flow phenomena were investigated utilizing conventional and focusing schlieren optics; furthermore, static and total pressure measurements were performed. The experiments supported the assumption that the system behavior can be described through a Fanno–Rayleigh flow model. Since only wavy walls with smooth profiles were involved, linearized gas dynamics was able to cover important flow features within the channel. The effects of the wavy wall structures on pressure drop and Mach number distribution within the flow path were investigated, and a good qualitative agreement with theoretical and numerical predictions was found. The present analysis demonstrates that pressure losses in pillow-plate heat exchangers are rather low, although their strong turbulent mixing enables high convective heat transfer coefficients. Full article

Stall and surge are strong limitations in the operating range of compressors and thus one of the major limits of jet engine performance. A promising way to push the stability limit of compression machines is to inject a small amount of flow at the blade tip to alter the physical mechanism responsible for stall onset. This study focuses on the experimental performance of such a system. To do so, an axial compressor test bench was equipped with 40 actuators connected to an auxiliary pressurised air supply system. They were able to generate high-speed jet blowing just at the tip of the rotor blades. The opening of each actuator was controlled by an electromagnetic valve. This allowed generating continuous or pulsed jets with frequencies up to 500 Hz at different duty cycles. The performance of the control system was investigated for various control strategies, where the injected flow rate, the injection angle, the number of injectors, the jet frequency and the duty cycle were systematically varied. This paper is concluded by a study of the energy balance of the system for various configurations. To the best of the authors’ knowledge, this constitutes a rarely seen analysis in the literature. Full article

Reynolds-Averaged Navier–Stokes (RANS) methods continue to be the backbone of CFD-based design; however, the recent development of high-order unstructured solvers and meshing algorithms, combined with the lowering cost of HPC infrastructures, has the potential to allow for the introduction of high-fidelity simulations in the design loop, taking the role of a virtual wind tunnel. Extensive validation and verification is required over a broad design space. This is challenging for a number of reasons, including the range of operating conditions, the complexity of industrial geometries and their relative motion. A representative industrial low pressure turbine (LPT) cascade subject to wake passing interactions is analysed, adopting the incompressible Navier–Stokes solver implemented in the spectral/hp element framework Nektar++. The bar passing effect is modelled by leveraging a spectral-element/Fourier Smoothed Profile Method. The Reynolds sensitivity is analysed, focusing in detail on the dynamics of the separation bubble on the suction surface as well as the mean flow properties, wake profiles and loss estimations. The main findings are compared with experimental data, showing agreement in the prediction of wake traverses and losses across the entire range of flow regimes, the latter within 5% of the experimental measurements. Full article

Modern aeroengine designs strive for peak specific fuel and thermal efficiency. To achieve these goals, engines have more highly loaded compressor stages, thinner aerofoils, and blended titanium integrated disks (blisks) to reduce weight. These configurations promote the occurrence of aeroelastic phenomena such as flutter. Two important parameters known to influence flutter stability are the reduced frequency and the ratio of plunge and pitch components in a combined flap mode shape. These are used as design criteria in the engine development process. However, the limit of these criteria is not fully understood. The following research aims to bridge the gap between semi-analytical models and modern compressors by systematically investigating the flutter stability of a linear compressor cascade. This paper introduces the plunge-to-pitch incidence ratio, which is defined as a function of reduced frequency and pitch axis setback for a first flap (1F) mode shape. Using numerical simulations, in addition to experimental validation, aerodynamic damping is computed for many modes to build stability maps. The results confirm the importance of these two parameters in compressor aeroelastic stability as well as demonstrate the significance of the plunge-to-pitch incidence ratio for predicting the flutter limit. Full article

Non-synchronous blade vibrations have been observed in an experimental multi-stage high-speed compressor setup at part-speed conditions. A detailed numerical study has been carried out to understand the observed phenomenon by performing unsteady full-annulus Reynolds-Averaged Navier–Stokes (RANS) simulations of the whole setup using the solver elsA. Several operating conditions have been simulated to observe this kind of phenomena along a speedline of interest. Based on the simulation results, the physical source of the non-synchronous blade vibration is identified: An aerodynamic disturbance appears in a highly loaded downstream rotor and excites a spinning acoustic mode. A “lock-in” phenomenon occurs between the blade boundary layer oscillations and the spinning acoustic mode. The establishment of axially propagating acoustic waves can lead to a complex coupling mechanism and this phenomenon is highly relevant in understanding the multi-physical interactions appearing in modern compressors. It is shown that aerodynamic disturbances occurring downstream can lead to critical excitation of rotor blades in upstream stages due to an axially propagating acoustic wave. The paper includes the analysis of a relevant transient test and a detailed analysis of the numerical results. The study shows the capability and necessity of a full-annulus multistage simulation to understand the phenomenon. Full article

The high pressure turbine nozzle guide vane of a modern aeroengine experiences large heat loads and thus requires both highly effective internal and external cooling. This can be accomplished with double-wall effusion cooling, which combines impingement, pin-fin and effusion cooling. The combination of three cooling mechanisms causes high pressure losses, increasing potential for the migration of coolant towards low pressure regions, subsequently starving effusion holes on the leading edge of coolant supply. This paper presents a low order flow network model to rapidly assess the pressure and mass flow distributions through such cooling schemes for a flexible set of geometric and flow conditions. The model is subsequently validated by a series of experiments with varying mainstream pressure gradients. Results from the model are used to indicate design parameters to reduce the effect of coolant migration, and to minimise the risk of destructive hot gas ingestion. Full article

The increasing introduction of renewable energy capacity has changed the perspective on the operation of conventional power plants, introducing the necessity of reaching extreme off-design conditions. There is a strong interest in the development and optimization of technologies that can be retrofitted to an existing power plant to enhance flexibility as well as increase performance and lower emissions. Under the framework of the European project TURBO-REFLEX, a typical F-class gas turbine compressor designed and manufactured by Ansaldo Energia has been studied. Numerical analyses were performed using the TRAF code, which is a state-of-the-art 3D CFD RANS/URANS flow solver. In order to assess the feasibility of lower minimum environmental load operation, by utilizing a reduction in the compressor outlet mass-flow rate, with a safe stability margin, two different solutions have been analyzed: blow-off extractions and extra-closure of Variable Inlet Guide Vanes. The numerical steady-state results are compared and discussed in relation to an experimental campaign, which was performed by Ansaldo Energia. The purpose is to identify the feasibility of the technologies and implementation opportunity in the existing thermal power plant fleet. Full article

This paper presents a critical overview on worst-case design scenarios for which low-speed axial flow fans may exhibit an increased risk of blade resonance due to profile vortex shedding. To set up a design example, a circular-arc-cambered plate of 8% relative curvature is investigated in twofold approaches of blade mechanics and aerodynamics. For these purposes, the frequency of the first bending mode of a plate of arbitrary circular camber is expressed by modeling the fan blade as a cantilever beam. Furthermore, an iterative blade design method is developed for checking the risky scenarios for which spanwise and spatially coherent shed vortices, stimulating pronounced vibration and noise, may occur. Coupling these two approaches, cases for vortex-induced blade resonance are set up. Opposing this basis, design guidelines are elaborated upon for avoiding such resonance. Based on the approach presented herein, guidelines are also developed for moderating the annoyance due to the vortex shedding noise. Full article

Pressure gain combustion is a promising alternative to conventional gas turbine technologies and within this class the Rotating Detonation Engine has the greatest potential. The Fickett–Jacobs cycle can theoretically increase the efficiency by 15% for medium pressure ratios, but the combustion chamber delivers a strongly non-uniform flow; in these conditions, conventionally designed turbines are inadequate with an efficiency below 30%. In this paper, an original mean-line code was developed to perform an advanced preliminary design of a supersonic turbine; self-starting capability of the supersonic channel has been verified through Kantrowitz and Donaldson theory; the design of the supersonic profile was carried out employing the Method of Characteristics; an accurate evaluation of the aerodynamic losses has been achieved by considering shock waves, profile, and mixing losses. Afterwards, an automated Computational Fluid Dynamics (CFD) based optimization process was developed to find the optimal loading condition that minimizes losses while delivering a sufficiently uniform flow at outlet. Finally, a novel parametric analysis was performed considering the effect of inlet angle, Mach number, reaction degree, peripheral velocity, and blade height ratio on the turbine stage performance. This analysis has revealed for the first time, in authors knowledge, that this type of machines can achieve efficiencies over 70%. Full article

To meet the challenges of increased thermal loads and performance demands on aero-engine turbine blades, more advanced cooling techniques are required. This study used a modification of the well-known Goldstein equation to predict film effectiveness for an individual film cooling hole and applied the Sellers’ superposition method to apply these films across effusion-cooled configurations. In doing so, it tackles a relatively unchallenged problem of film holes in close spanwise proximity. An experimental set-up utilised infrared cameras to assess the film effectiveness of nine geometries of varying spanwise and streamwise spacings. Higher porosity led to increased thermal protection, and the spanwise spacing had the most profound impact, with film effectiveness approaching 0.9. Additionally, greater uniformity in the spanwise direction was observed. The modified Goldstein-Sellers method showed good agreement with experimental results although lateral mixing was underestimated. This method represents a tool that could be easily implemented in the industry for rapid assessment of novel cooling geometries. Full article

In stator–rotor interaction studies on axial turbines, the attention is commonly focused on the unsteady rotor aerodynamics resulting from the periodic perturbations induced by the stator flow structures. Conversely, less interest has been historically attracted regarding the influence of the rotor on the flow released by the stator, correlated to propagation of the blade potential field upstream of the rotor leading edge. In this paper, experiments in the research high-pressure turbine of the Laboratory of Fluid-Machines of the Politecnico di Milano, performed by applying a fast-response aerodynamic pressure probe, alongside fully-3D time-accurate CFD simulations of the flow, are combined with the aim of discussing the rotor-to-stator interaction. While rotating, the rotor induces periodic perturbations on the pressure and velocity field in the stator–rotor gap, altering the evolution of the total quantities and the flow rate discharged by each stator channel and eventually triggering energy-separation effects which result in total pressure and total temperature oscillations in the stator-exit flow. Such oscillations were found to rise up to almost ±10% of the stage total temperature drop. Full article

This paper addresses the problem of the design optimization of turbomachinery components under thermo-mechanical constraints, with focus on a radial turbine impeller for turbocharger applications. Typically, turbine components operate at high temperatures and are exposed to important thermal gradients, leading to thermal stresses. Dealing with such structural requirements necessitates the optimization algorithms to operate a coupling between fluid and structural solvers that is computationally intensive. To reduce the cost during the optimization, a novel multiphysics gradient-based approach is developed in this work, integrating a Conjugate Heat Transfer procedure by means of a partitioned coupling technique. The discrete adjoint framework allows for the efficient computation of the gradients of the thermo-mechanical constraint with respect to a large number of design variables. The contribution of the thermal strains to the sensitivities of the cost function extends the multidisciplinary outlook of the optimization and the accuracy of its predictions, with the aim of reducing the empirical safety factors applied to the design process. Finally, a turbine impeller is analyzed in a demanding operative condition and the gradient information results in a perturbation of the grid coordinates, reducing the stresses at the rotor back-plate, as a demonstration of the suitability of the presented method. Full article

An algebraic intermittency model for boundary layer flow transition from laminar to turbulent state, is extended using an experimental data base on boundary layer flows with various transition types and results by large eddy simulation of transition in a separated boundary layer. The originating algebraic transition model functions well for bypass transition in an attached boundary layer under a moderately high or elevated free-stream turbulence level, and for transition by Kelvin–Helmholtz instability in a separated boundary layer under a low free-stream turbulence level. It also functions well for transition in a separated layer, caused by a very strong adverse pressure gradient under a moderately high or elevated free-stream turbulence level. It is not accurate for transition in a separated layer under a moderately strong adverse pressure gradient, in the presence of a moderately high or elevated free-stream turbulence level. The extension repairs this deficiency. Therefore, a sensor function for detection of the front part of a separated boundary layer activates two terms that express the effect of free-stream turbulence on the breakdown of a separated layer, without changing the functioning of the model in other flow regions. The sensor and the breakdown terms use only local variables. Full article

Modern aero-engine combustion chambers burn a lean and premixed mixture, generating a turbulent flame which involves large heat-release fluctuations, thus producing unsteady temperature phenomena commonly referred to as entropy waves (EWs). Furthermore, to enhance the fuel air mixing, combustion air is swirled, leading to vorticity disturbances. These instabilities represent one of the biggest challenges in gas turbine design. In this paper, the design and testing of a novel entropy wave generator (EWG) equipped with a swirler generator (SG) are described. The novel EWG will be used in future works on the high-speed test rig at Politecnico di Milano to study the combustor–turbine interaction. The paper shows the process of the EWG geometry and layout. The EWG is able to produce an engine-representative EW, the extreme condition is at the maximum frequency of 110 Hz, a peak-to-valley temperature value of 20 °C and swirling angles of ±25° are measured. By virtue of these results, the proposed system outperforms other EWG devices documented in the literature. Furthermore, the addition of a swirling generator makes this device one of a kind. Full article

In modern aircraft engines, the low-pressure compressor (LPC) is subjected to a flow characterized by strong wakes and secondary flows from the upstream fan. This concerns ultra-high bypass ratio (UHBR) turbofan engines, in particular. This paper presents the aerodynamic and aeroelastic sensitivities of parametric variations on the LPC, driven by the design considerations in the upstream fan. The goal of this investigation was to determine the influence of design-based geometry parameter variations on the LPC performance under realistic inlet flow distributions and the presence of an s-duct. Aerodynamic simulations are conducted at the design and off-design operating points with the fan outflow as the inlet boundary conditions. Based on the aerodynamic results, time-linearized unsteady simulations are conducted to evaluate the vibration amplitude at the resonance operating points. First, the bypass ratio is varied by reducing the channel height of the LPC. The LPC efficiency decreases by up to $1.7\%$ due to the increase in blockage of the core flow. The forced response amplitude of the rotor decreases with increasing bypass ratio due to increased aerodynamic damping. Secondly, the fan cavity leakage flow is considered as it directly affects the near hub fan flow and thus the inflow of the LPC. This results in an increased total-pressure loss for the s-duct due to mixing losses. The additional mixing redistributes the flow at the s-duct exit leading to a total-pressure loss reduction of $4.3\%$ in the first rotor at design point. This effect is altered at off-design conditions. The vibration amplitude at low speed resonance points is increased by $19\%$ for the first torsion and $26\%$ for second bending. Thirdly, sweep and lean are applied to the inlet guide vane (IGV) upstream of the LPC. Despite the s-duct and the variable inlet guide vane (VIGV) affecting the flow, the three-dimensional blade design achieves aerodynamic and aeroelastic improvements of rotor 1 at off-design. The total-pressure loss reduces by up to $18\%$ and the resonance amplitude more than $10\%$. Only negligible improvements for rotor 1 are present at the design point. In a fourth step, the influence of axial gap size between the stator and the rotor rows in the LPC is examined in the range of small variations which shows no distinct aerodynamic and aeroelastic sensitivities. This finding not only supports previous studies, but it also suggests a correlation between mode shapes and locally increased excitaion with increasing axial gap size. As a result, potential design improvements in future fan-compressor design are suggested. Full article

In this paper, the deployment of a newly developed, multipoint, fiber-optic temperature-sensor system for temperature distribution measurements in a 6 MW gas turbine is demonstrated. The optical sensor fiber was integrated in a stainless steel protection cable with a 1.6 mm outside diameter. It included six measurement points, distributed over a length of 110 mm. The sensor cable was mounted in a temperature probe and was positioned radially in the exhaust-gas diffusor of the turbine. With this temperature probe, the radial temperature profiles in the exhaust-gas diffusor were measured with high spatial and temporal resolution. During a test run of the turbine, characteristic temperature gradients were observed when the machine operated at different loads. Full article

Aerothermal heat transfer measurements in fluid dynamics have a relatively high acceptance of uncertainty due to the intricate nature of the experiments. The large velocity and pressure gradients present in turbomachinery application add further complexity to the measurement procedure. Recent method and manufacturing development has addressed some of the primary sources of uncertainty in these heat transfer measurements. However, new methods have so far not been applied in a holistic approach for heat transfer studies. This gap is bridged in the present study where a cost-effective and highly accurate method for heat transfer measurements is implemented, utilising infrared thermography technique (IRT) for surface temperature measurement. Novel heat transfer results are obtained for the turbine rear sturcture (TRS), at engine representative conditions for three different outlet guide vane (OGV) blade loading and at Reynolds Number of 235000. In addition to that, an extensive description of the implementation and error mitigation is presented. Full article

The present study focuses on the impact of the underlying RANS turbulence model in the Zonal Detached Eddy Simulation (ZDES) method when used for secondary flow prediction. This is carried out in light of three issues commonly investigated for hybrid RANS/LES methods (detection and protection of attached boundary layer, emergence, and growth of resolved turbulent fluctuations and accurate prediction of separation front due to progressive adverse pressure gradient). The studied configuration is the first rotor of a high pressure compressor. Three different turbulence modelings (Spalart and Allmaras model (SA), Menter model with (SST) and without (BSL) shear stress correction) are assessed as ZDES underlying turbulence model and also as turbulence model of unsteady RANS simulations. Whatever the underlying turbulence model, the ZDES behaves well with respect to the first two issues as the boundary layers appear effectively shielded and the RANS-to-LES switch is close downstream of trailing edges and separation fronts leading to a quick LES treatment of wakes and shear layers. Both tip leakage and corner flows are strongly influenced by the Navier–Stokes resolution approach (unsteady RANS vs. ZDES) but the underlying turbulence modelling (SA vs. SST vs. BSL) impacts mainly the junction flow near the hub for both approaches. ZDES underlying turbulence model choice appear essential since it leads to quite different corner flow separation topologies and so to inversion of the downstream stagnation pressure radial gradient. Full article

In the majority of compressible flow CFD simulations, the standard ideal gas state equation is accurate enough. However, there is a range of applications where the deviations from the ideal gas behaviour is significant enough that performance predictions are no longer valid and more accurate models are needed. While a considerable amount of the literature has been written about the application of real gas state equations in CFD simulations, there is much less information on the numerical issues involved in the actual implementation of such models. The aim of this article is to present a robust implementation of real gas flow physics in an in-house, coupled, pressure-based solver, and highlight the main difference that arises as compared to standard ideal gas model. The consistency of the developed iterative procedures is demonstrated by first comparing against results obtained with a framework using perfect gas simplifications. The generality of the developed framework is tested by using the parameters from two different real gas state equations, namely the IAPWS-97 and the cubic state equations state equations. The highly polynomial IAPWS-97 formulation for water is applied to a transonic nozzle case where steam is expanded at transonic conditions until phase transition occurs. The cubic state equations are applied to a two stage radial compressor setup. Results are compared in terms of accuracy with a commercial code and measurement data. Results are also compared against simulations using the ideal gas model, highlighting the limitations of the later model. Finally, the effects of the real gas formulations on computational time are compared with results obtained using the ideal gas model. Full article

In the near future, when designing and using Double Wall Airfoils, which will be manufactured by 3D printers, the positional relationship between the impingement cooling nozzle and the heat transfer enhancement ribs on the target plate naturally becomes more accurate. Taking these circumstances into account, an experimental study was conducted to enhance the heat transfer of the wall jet region of a round impingement jet cooling system. This was done by installing circular ribs or vortex generators (VGs) in the impingement cooling wall jet region. The local heat transfer coefficient was measured using the naphthalene sublimation method, which utilizes the analogy between heat and mass transfer. As a result, it was clarified that, within the ranges of geometries and Reynolds numbers at which the experiments were conducted, it is possible to improve the averaged Nusselt number Nu up to 21% for circular ribs and up to 51% for VGs. Full article

The present paper aims at evaluating the surveillance parameters used for early stall warning in axial compressors, and is based on unsteady pressure measurements at the casing of a single stage axial compressor. Two parameters—Correlation and Root Mean Square (RMS)—are first compared and their relative performances discussed. The influence of sensor locations (in both radial and axial directions) is then considered, and the role of the compressor’s geometrical irregularities in the behavior of the indicators is clearly highlighted. The influence of the throttling process is also carefully analyzed. This aspect of the experiment’s process appears to have a non-negligible impact on the stall warning parameters, despite being poorly documented in the literature. This last part of this research work allow us to get a different vision of the alert parameters compared to what is classically done in the literature, as the level of irregularity that is reflected by the magnitude of the parameters appears to be an image of a given flow rate value, and not a clear indicator of the stall inception. Full article

The need for better combustion monitoring in gas turbines has become more acute with the latest technical requirements, standards, and policies in terms of safety, environment, efficiency, operation flexibility, and operation costs. Combustion Bay One e.U. and FH JOANNEUM GmbH initiated in 2015 an experimental research program about the feasibility and first assessments of placing optical systems near the combustor. The project’s acronym “emootion” stands for “Engine health MOnitOring and refined combusTION control based on optical diagnostic techniques embedded in the combustor”. The motivation of the project is twofold. On one side, one wants to exploit the radiative feature of the flame and to transform it into a piece of reliable information about the combustion status. On the other side, this information can be useful in terms of data interpretation or data reconciliation with other information coming from other sensors such as temperature probes, fast pressure probes, or accelerometers. The focus is put on several aspects of combustor operations: on detection of the flame, on monitoring of the ignition process, on a quality assessment of combustion based on its spectral contents (including soot formation), and on the detection of possible combustion instabilities. Promising results were obtained using photodiodes that offer an adequate trade-off between narrow-band sensitivity and signal time response. It is shown that it is convenient to combine a fast-pressure sensor with an optical sensor in a compact form; this combination has led to the so-called Rayleigh Criterion Probe (RCP). The split in red, green, and blue (RGB) light components and their further analysis allows for mapping the different types of operation. Regarding the probe packaging aspect, it is discussed that the level of light collection needed to keep an acceptable signal-to-noise ratio has been so far a restraint for the use of optical fibres. Solutions are proposed to bring the optical sensor as close as possible to the optical interface and to make it operational and reliable in prevailing heat. This contribution closes with a description of the pressure tests in a new combustion facility built for this purpose. A compact and portable combustion monitoring system including at least 3 RCPs can become an instrumentation standard within the next decade. Full article

The paper presents a state-of-the-art review of turbine trailing edge flows, both from an experimental and numerical point of view. With the help of old and recent high-resolution time resolved data, the main advances in the understanding of the essential features of the unsteady wake flow are collected and homogenized. Attention is paid to the energy separation phenomenon occurring in turbine wakes, as well as to the effects of the aerodynamic parameters chiefly influencing the features of the vortex shedding. Achievements in terms of unsteady numerical simulations of turbine wake flow characterized by vigorous vortex shedding are also reviewed. Whenever possible the outcome of a detailed code-to-code and code-to-experiments validation process is presented and discussed, on account of the adopted numerical method and turbulence closure. Full article

A siren is a robust fast-valve that generates effective flow pulsations and powerful noise levels under well-controlled conditions. It operates under the inlet flow conditions of a gas turbine combustor. Its principle is based on a sonic air jet periodically sheared by a cogged wheel rotating at a given speed. It is used as an alternative to loudspeakers in combustion laboratories when the use of these is made difficult by aggressive flow conditions, such as hot air under pressure, possibly containing impurities. It is also a serious candidate as an effective flow actuator to be deployed on power gas turbine fleets. The authors have gathered more than twenty years of knowledge on siren technology. This pulsator was originally developed for research on thermoacoustics. By scanning through a given frequency range, one detects the acoustic resonance of specific parts of the combustor assembly, or possibly triggers a combustion instability during a sensitivity analysis of a flame to small perturbations. In 2010, Giuliani et al. developed a novel siren model with the capacity to vary the amplitude of pulsation independently from the frequency. In this contribution, the physics, the metrics, and the resulting parameters of the pulsator are discussed. Technical solutions are unveiled about visiting large frequency ranges (currently 6 kHz) and achieving elevated pressure fluctuations (150 dB SPL proven, possibly up to 155 dB SPL) with a compact device. A multimodal excitation is available with this technology, one idea being to dissipate the acoustic energy on nearby peaks. The contribution ends with a summary of the applications performed so far and the perspective of an industrial application. Full article

This paper presents and discusses the recent developments on the Fast-Response Aerodynamic Pressure Probe (FRAPP) technology at the Laboratorio di Fluidodinamica delle Macchine (LFM) of the Politecnico di Milano. First, the different geometries developed and tested at LFM are presented and critically discussed: the paper refers to single-sensor or two-sensor probes applied as virtual 2D or 3D probes for phase-resolved measurements. The static calibration of the sensors inserted inside the head of the probes is discussed, also taking into account for the temperature field of application: in this context, a novel calibration procedure is discussed and the new manufacturing process is presented. The dynamic calibration is reconsidered in view of the 15-years’ experience, including the extension to probes operating at different temperature and pressure levels with respect to calibration. As for the probe aerodynamics, the calibration coefficients are discussed and the most reliable set here is evidenced. A novel procedure for the quantification of the measurement uncertainty, recently developed and based on the Montecarlo methodology, is introduced and discussed in the paper. Full article

High-fogging is widely used to rapidly increase the power outputs of stationary gas turbines. Therefore, water droplets are injected into the inflow air, and a considerable number enter the compressor. Within this paper, the primary process of droplet evaporation is investigated closely. A short discussion about the influential parameters ascribes a major significance to the slip velocity between ambient gas flow and droplets. Hence, experimental results from a transonic compressor cascade are shown to evaluate the conditions in real high-fogging applications. The measured parameter range is used for direct numerical simulations to extract evaporation rates depending on inflow conditions and relative humidity of the air flow. Finally, an applicable correlation for the Sherwood number in the form of $Sh(R{e}^{1/2}S{c}^{1/3})$ is suggested. Full article

State-of-the-art centrifugal compressor units utilised in pipeline and in energy storage applications face the challenge of flexible and highly efficient operation. Geometric contouring on the hub side near a vaned diffuser affects the flow in a way which increases operational flexibility by delaying the incipience of instability and thereby increases compressor operating range. In the present paper, a hub-side wall contouring is applied within the vaneless space and the vaned diffuser of an open impeller centrifugal compressor stage. The performance characteristic of the novel hub contouring is evaluated in a scale-model test rig and compared against a baseline design. A stable operating range increase of 8% is achieved for the contoured design at ${\mathrm{Mu}}_{\mathbf{2}}=$ 1.16. 5-hole probe measurements covering a complete diffuser blade-to-blade passage are performed upstream the diffuser and compared both against CFD simulations and against the measurements of the baseline design for an operating point near the stability limit. Full article

The flow in the vaned diffuser of an aeronautical centrifugal compressor designed by Safran Helicopter Engines is analyzed through steady and unsteady pressure measurements at different rotation speeds. The analysis leads to the identification of different operating zones thanks to a new variable, the alternate rate $\mathcal{A}$. It allows the characterization of a specific behavior of the vaned diffuser consisting of an alternate stall pattern in two adjacent channels of the diffuser. While it is close to zero at low speed, the alternate rate reaches a maximum value at a higher speed before collapsing with a further increase in the rotation speed. Depending on the value reached by the alternate rate, three distinct regimes of the flow within the diffuser can be distinguished. For low $\mathcal{A}$ values, the regime is the most common one with an equivalent flow pattern in each channel of the diffuser. For moderate $\mathcal{A}$ values, a mild difference of the flow fields which develop in two adjacent channels can be observed but it remains time independent. Finally, for high values of $\mathcal{A}$, the alternate pattern is amplified and becomes time dependent, pulsating together with the mild surge of the entire compressor. Full article

This paper presents a focusing schlieren system designed for the investigation of transonic turbine tip-leakage flows. In the first part, the functional principle and the design of the system are presented. Major design considerations and necessary trade-offs are discussed. The key optical properties, e.g., depth of focus, are verified by means of a simple bench test. In the second part, results of an idealized tip-clearance model as well as linear cascade tests at engine representative Reynolds and Mach numbers are presented and discussed. The focusing schlieren system, designed for minimum depth of focus, has been found to be well suited for the investigation of three-dimensional transonic flow fields in turbomachinery applications. The schlieren images show the origin and growth of the tip-leakage vortex on the blade suction side. A complex shock system was observed in the tip region, and the tip-leakage vortex was found to interact with the suction side part of the trailing edge shock system. The results indicate that transonic vortex shedding is suppressed in the tip region at an exit Mach number around ${\mathrm{M}}_{2,is}$ = 0.8. Full article