Search Results (60)

Turbines are rotating machines that generate power by the expansion of a fluid; due to their characteristics, these turbomachines are widely applied in aerospace propulsion systems. Due to the clearance between the rotor blade tip and casing, there is a leakage flow from the blade pressure to the suction sides, which generates energy loss. There are different strategies that can be applied to avoid part of this loss; one of them is the application of so-called desensitization techniques. The application of these techniques on gas turbines has been widely evaluated; however, there is a lack of analyses of hydraulic turbines. This study is a continuation of earlier analyses conducted during the first stage of the hydraulic axial turbine used in the low-pressure oxidizer turbopump (LPOTP) of the space shuttle main engine (SSME). The previous work analyzed the application of squealer geometries at the rotor tip. In the present paper, winglet geometry techniques are investigated based on three-dimensional flowfield calculations. The commercial CFX v.19.2 and ICEM v.19.2 software were used, respectively, on the numerical simulations and computational mesh generation. Experimental results published by the National Aeronautics and Space Administration (NASA) and data from previous works were used on the computational model validation. The parametric analysis was conducted by varying the thickness and width of the winglet. The results obtained show that by increasing the winglet thickness, the stage efficiency is also increased. However, the geometric dimension of its width has minimal impact on this result. An average efficiency increase of 2.0% was observed across the entire turbine operational range. In the case of the squealer, for the design point, the maximum efficiency improvement was 1.62%, compared to the current improvement of 2.23% using the winglet desensitization technique. It was found that the proposed geometries application also changes the cavitation occurrence along the stage, which is a relevant result, since it can impact the turbine life cycle. Full article

In aerospace applications, engine parts, especially those around the rotor blade tips, are coated with an abradable seal, a specific material layer. Its design produces a tighter seal without harming the blades by allowing it to wear down or “abrade” somewhat when the blade tips come into contact. In turbines and compressors, this reduces gas leakage between high- and low-pressure zones, increasing engine efficiency. Abradable seals are crucial to contemporary jet engines because they enhance performance and lower fuel consumption. The materials selected for these seals are designed to balance durability and abrasion resistance under high temperatures and speeds. Metal matrix, oxide particles, and porosity are the three most prevalent phases. An ideal mix of characteristics, such as hardness and erosion resistance, determines how effective a seal is, and this is accomplished by keeping the right proportions of elements in place throughout production. The primary objective of this research is to optimize abradability by utilizing various FEM tools to simulate the rub rig test and modify testing parameters, including Young’s modulus, yield stress, and tangent modulus, to analyze their impact on the wear behavior of the abradable seal and blade. Two microstructure models (CoNiCrAlY–BN–polyester coating) were found to perform optimally at porosity levels of 56% and 46%, corresponding to hardness values of 48 HR15Y and 71 HR15Y, respectively. Changing factors like yield stress and tangent modulus makes the seal more abrasive while keeping its hardness, porosity, and Young’s modulus the same. Furthermore, altering the Young’s modulus of the shroud material achieves optimal abradability when tangent modulus and yield stress remain constant. These findings provide valuable insights for improving material performance in engineering applications. To improve abradability and forecast characteristics, this procedure entails evaluating the effects of every single parameter setting, culminating in the creation of the best abradable materials. This modeling technique seems to provide reliable findings, providing a solid basis for coating design in the future. Full article

The axial compressor is crucial for heavy-duty gas turbines, with its aerodynamic performance directly affecting efficiency. The current trend in the development of these compressors is to increase the stage load and efficiency, thereby achieving a higher pressure ratio with fewer stages. The aerodynamic characteristics of a 1.5-stage axial compressor from a 300 MW F-class heavy gas turbine at three different rotation speeds (100%, 90%, and 80%) were studied. Specifically, the distribution of the inlet Mach number, shock wave structures, isentropic Mach number of blade surface, and blade surface separation flow characteristics under three typical working conditions, at the near stall (NS) point, maximum efficiency (ME) point, and near choke point (NC), were discussed. The results indicate that at 80% rotational speed, 70~100% spanwise of the compressor rotor blade is operated under the transonic zone. Meanwhile, at 100% rotational speed, almost all the spanwise of the compressor rotor blade is operated under the transonic zone. Furthermore, compared to the detached shock wave observed under the NS condition, the normal passage shock wave observed under the NC condition exhibits more significant changes in shock intensity and shock pattern. Full article

Turbine engines are currently one of the most important and expensive aircraft components. Both for economic and safety reasons, high engine reliability is required. Therefore, sophisticated methods are needed to determine their current condition. Diagnostics of turbine engines allow for the detection of faults before they lead to damage. The article presents methods and results of vibroacoustic diagnostics of a miniature GTM400 jet engine adapted to kerosene and hydrogen fuel supply. During thermal and vibroacoustic tests of engine parameters powered by hydrogen fuel supply, the engine seized up in the initial start-up phase due to improper control and rapid thermal changes in the gas line. The cause of the undesirable technical condition of the engine was a significantly higher temperature of gases (exhaust gases) affecting the working elements of the engine (turbine shaft, rotor, and blades), which consequently led to engine damage. This phenomenon and the results obtained from the unexpected technical condition constitute a valuable premise for considering the issue of proper operation of the turbojet engine during fuel changes, especially following current trends related to the decarbonization of the aviation sector. The obtained research results and the resulting observations and conclusions make it necessary to perform technical analyses and pre-implementation tests each time before allowing the use of a conventional engine if it undergoes the process of reconstruction in terms of using a new fuel (especially if its technical parameters are different from the originally used one). The presented method of conducting tests allows for a detailed determination of the causes of damage to the cooperating elements of the engine structure under the influence of changes in operating parameters. Full article

The implementation of serrated stator blades in axial compressor and fan stages offers significant advantages, such as enhanced performance and reduced noise levels, making it a practical and cost-effective solution. This study explores the impact of serrated blade design on noise reduction under specific engine operating conditions. A small-scale experimental test setup with a turbulence-inducing grid was designed for testing multiple grid sizes in order to identify the most promising configuration which replicates rotor–stator interaction. Numerical simulations and early experimental tests in an anechoic chamber using a four-blade cascade configuration at an airflow speed of 50 m/s revealed a small but notable noise reduction in the 1–6 kHz range for a partially matched grid–blade geometry. Serrated blades demonstrated an overall sound pressure level reduction of 1.5 dB and up to 12 dB in tonal noise, highlighting the potential of cascade configurations to improve acoustic performance in gas turbine applications. Full article

To achieve higher thermal efficiency in a gas turbine, increasing the turbine inlet temperature is necessary. The rotor blade at the first stage tolerates the highest temperature, and the serpentine internal channel located in the middle chord of the rotor blade is vital in guaranteeing the blade’s service life. Therefore, it is essential to illustrate the evolution of the rotating internal channel in a gas turbine blade. In the paper, the influence of the Coriolis force, including its mechanisms, on the conventional rotating channel are reviewed and analyzed. A way to utilize the positive heat transfer effect of the Coriolis force is proposed. Recent investigations on corresponding novel rotating channels with a channel orientation angle of 90° (called bilaterally enhanced U-channels) are illustrated. Moreover, numerical investigations about the Re effects on bilaterally enhanced smooth U-channels were carried out in the study. The results indicated that bilaterally enhanced U-channels can utilize the Coriolis force positive heat transfer effect on the leading and the trailing walls at the same time. Re and Ro are vital non-dimensional numbers that influence the performance of bilaterally enhanced U-channels. Re and Ro have an independent influence on the heat transfer performance of the bilaterally enhanced U-channel. Ro is good for the heat transfer of the bilaterally enhanced U-channel on both the leading and the trailing walls. Therefore, the bilaterally enhanced U-channel is suitable for application in the middle chord region of a turbine blade, since it can utilize the rotation effect of the rotating blade to improve the heat transfer ability of the blade and thus reduced the blade temperature. At the same Ro, Re positively affects the Nu on the leading and the trailing walls of the Coriolis-utilization rotating smooth U-channel, but plays a negligible role on Nu/Nu₀. Full article

Current and future heavy-duty gas turbines (GTs) are being developed as an alternative or support to renewable energy sources (RESs). Therefore, GTs are subjected to several instances of being switched on and off; thus, the material fatigue limit can be reached in a short time. In such a scenario, possible out-of-tolerances (OoTs) in critical components must be considered. In this paper, OoTs related to critical parameters in the attachment geometry of a rotor blade are considered to estimate their impact on component life through a 2D finite element (FE) analysis. First, a mesh refinement is performed to obtain mesh-independent results; second, OoT geometries are simulated to determine stresses and strains at the blade attachment and disc groove. The mesh refinement process is critical to ensure model accuracy for both nominal and OoT geometries. The results show that OoTs can lead to important reductions in the life of the intended component, both on the blade and disc sides. These results could be useful in updating the maintenance plan for components and could be used for future insights, with further work extending the study to 3D geometry, for example, and evaluating the effect of other geometries. Full article

The compressor serves as a crucial component that influences the performance of the gas turbine engine. Researchers have been endeavoring to explore compressor types that possess a high loading level and high-efficiency characteristics concurrently. In this study, tandem blade technology was applied to a transonic ultra-highly loaded axial compressor, and the Baseline single-blade rotor was replaced by a tandem rotor to take into account the loading level and compressor performance. Detailed investigations were carried out to identify the effects on the aerodynamic performance of the ultra-highly loaded stage and the fundamental flow mechanism within the tandem-rotor stage. This paper presents original design maps for the tandem-rotor stage, and the selection criteria for tandem parameters in tandem-rotor stage are refined. The results indicate that the peak efficiency improved by 0.83%, the stall margin increased by 2.16%, and the choke flow rate rose by 0.30% for the optimal tandem-rotor configuration. The meridional division position of the rotor primarily affects the ratio of loading of the front and rear blades, while the circumferential relative position of the tandem rotor mainly influences the channel types formed by the front and rear blades. Larger values for the meridional division position parameter and smaller values for circumferential relative position parameter should be selected for the tandem rotor design to optimize both the isentropic efficiency and total pressure ratio. This investigation offers the theoretical foundation for the design of a transonic ultra-highly loaded tandem-rotor compressor. Full article

Upgrading abradable or wearable coatings in the high-temperature zone of aero engines is advised to increase the efficiency and high-density power in gas turbine engines for military or commercial fixed-wing and rotary-wing aircraft. The development of these coated materials is also motivated by minimization of the number of failures in the blade, as well as increasing their resistance to wear and erosion. It is suggested that abradable coatings or seals be used to accomplish this goal. The space between the rotor and the shroud is minimized thanks to an abradable seal at the blade’s tip. Coatings that can withstand abrasion are often multiphase materials sprayed through thermal spray methods, and which consist of a metal matAzmeerix, oxide particles, and void space. The maintenance of an ideal blend of qualities, such as erosion resistance and hardness, during production determines a seal’s effectiveness. The objective of this research is to develop microstructure-based modelling methodology which will mimic the coating wear process and subsequently help in designing the abradable coating composition. Microstructure modelling, meshing, and wear analysis using many tools such as Fusion360, Hyper Mesh, and LS-Dyna, have been employed to develop an abradable coating model and perform wear analysis using a simulated rub rig test. The relation between percentage composition and morphology variations of metal, oxide, and voids to the output parameters such as hardness, abradability, and other mechanical properties is explored using simulated finite analysis models of real micrographic images of abradable coatings. Full article

Turbine inlet temperatures in advanced gas turbines could be as high as 2000 °C. To prevent ingress of this hot gas into the wheelspace between the stator and rotor disks, whose metals can only handle temperatures up to 850 °C, rim seals and sealing flows are used. This study examines the abilities of large eddy simulation (LES) based on the WALE subgrid model and Reynolds-averaged Navier–Stokes (RANS) based on the SST model in predicting ingress in a rotor–stator configuration with vanes but no blades, a configuration with experimental data for validation. Results were obtained for an operating condition, where the ratio of the external Reynolds number to the rotational Reynolds number is 0.538. At this operating condition, both LES and RANS were found to correctly predict the coefficient of pressure, C_p, located downstream of the vanes and upstream of the seal, but only LES was able to correctly predict the sealing effectiveness. This shows C_p by itself is inadequate in quantifying externally induced ingress. RANS was unable to predict the sealing effectiveness because it significantly under predicted the pressure drop in the hot gas path along the axial direction, especially about the seal region. This affected the pressure difference across the seal in the radial direction, which ultimately drives ingress. Full article

Off-design condition of a rotor blade cascade with and without platform cooling was experimentally investigated. The ability of the gas turbine to operate down to 50% to 20% of its nominal intake air flow rate has an important consequence in the change in the inlet incidence angle, which varied from nominal to −20°. Platform cooling through an upstream slot simulating the stator-to-rotor interface gap was considered. The impact of rotation on purge flow injection was simulated by installing fins inside the slot to give the coolant flow a tangential direction. Aerodynamic measurements to quantify the cascade aerodynamic loss and secondary flow structures were performed at Ma_2is = 0.55, varying the coolant to main flow mass flow ratio (MFR%) and the incidence angle. The results show that losses strongly increase with MFR. A negative incidence allows a reduction in the overall loss even when coolant is injected with a high MFR. The more negative the incidence, the greater the loss reduction. Full article

The purpose of the paper is to characterize the aerodynamic behavior of a rotor-downstream hub cavity rim seal in a high-pressure turbine (HPT) stage. The experimental data are acquired in the Transonic Test Turbine Facility at the Graz University of Technology: the test setup includes two engine-representative turbine stages (the last HPT stage and first LPT stage), with the intermediate turbine duct in between. All stator-rotor cavities are supplied with purge flows by a secondary air system, which simulates the bleeding air from the compressor stages of the real engine. The HPT downstream hub cavity is provided with wall taps and pitot tubes at different radial and circumferential locations, which allows the performance of steady pressure and seed gas concentration measurements for different purge mass flows and HPT vanes clocking positions. Moreover, miniaturized pressure transducers are adopted to evaluate the unsteady pressure distribution, and an oil flow visualization is performed to retrieve additional information on the wheel space structures. The annulus pressure asymmetry depends on the HPT vane clocking, but this is shown to have negligible impact on the minimum purge mass flow required to seal the cavity. However, the hub pressure profile drives the distribution of the cavity egress in the turbine channel. The unsteady pressure field is dominated by blade-synchronous oscillations. No non-synchronous components with comparable intensity are detected. Full article

This study presents the development of a design method that has been extended to the design of radial-inflow turbines operating in organic Rankine cycles (ORC). Both the conventional design method and the circulation method available in the literature have been reviewed. The two main limitations of the current circulation method that make it not suitable for the ORC turbine design are the lack of real gas capability and 3D blades with high stresses. Using the circulation method, the flow field is decomposed into a potential part and a rotational part. The mean velocity field and the periodic velocity field are solved separately. To model the thermodynamic properties of the real gas, NIST REFPROP or CoolProp are used. The blade geometry is then solved iteratively by assuming that the velocity vector is parallel to the blade surface. The blade boundary condition is modified to force the blade camber to be radial-fibred, which is helpful to reduce the centrifugal bending stress on the blade. All the formulations are derived step by step, and the numerical treatments, including grid generation, numerical differentiation, computational scheme, and convergence, are discussed in detail. This method is validated by designing a R245fa ORC turbine rotor. The performance of the rotor design is predicted by CFD and FEA simulations, and it is compared to the results using other methodologies in the literature. Full article

In gas turbines, the hot gas exiting the combustor can have temperatures as high as 2000 °C, and some of this hot gas enter into the space between the stator and rotor disks (wheelspace). Since the entering hot gas could damage the disks, its ingestion must be minimized. This is carried out by rim seals and by introducing a cooler flow from the compressor (sealing flow) into the wheelspace. Ingress and egress into rim seals are driven by the stator vanes, the rotor and its rotation, and the rotor blades. This study focuses on the ingress and egress driven by the rotor and its rotation. This is carried out by performing wall-resolved large eddy simulation (LES) around an axial seal in a rotor–stator configuration without vanes and blades. Results obtained show the mechanisms by which the rotor and its rotation induce ingress, egress, and flow trajectories. Kelvin–Helmholtz instability was found to create a wavy shear layer and displacement thickness that produces alternating regions of high and low pressures around the rotor side of the seal. Vortex shedding on the backward-facing side of the seal and its impingement on the rotor side of the seal also produces alternating regions of high and low pressures. The locations of the alternating regions of high and low pressures were found to be statistically stationary and to cause ingress to start on the rotor side of the seal. Vortex shedding and recirculating flow in the seal clearance also cause ingress by entrainment. With the effects of the rotor and its rotation on ingress and egress isolated, this study enables the effects of stator vanes and rotor blades to be assessed. Full article

The reliability and operational safety of an aircraft engine gas turbine are extremely important in terms of its operation. In the course of operation, these turbines undergo complex thermal, mechanical, aerodynamic, and chemical exhaust gas loads. Due to such a load, particularly acting upon the rotor blades, they undergo various damages. Therefore, the maintenance processes continuously strive for enhancing diagnostic methods in order to improve the sensitivity and reliability of damage identification. The basic diagnostic method is a visual one, supported by an optoelectronic device. It only enables determining the fact of a damage, e.g., mechanical, thermal, or chemical. The turbine blade material degradation degree is very difficult to assess in a nondestructive manner in the course of engine operation. No objective, and yet nondestructive, diagnostic method enabling the assessment of blade alloy structural changes has been developed so far. Therefore, a thesis was put forward that it was possible to apply the visual method and correlate its results with the results of gas turbine blade microstructural change tests, which would enable detecting early damage phases and assessing their fitnesses. The tests were conducted with the laboratory method. The authors received new blades of the SO-3 aircraft gas turbine engine made of the EI-867 WD alloy and then subjected them to heating in a laboratory furnace, over a temperature range of T = 1123–1523 K, in increments of 100 K. Cooling took place in the furnace. Prior to and after heating, the blades were subjected to visual testing. Blade surface colour is a diagnostic symptom which indicates a change in the blades’ technical condition. The images were analysed using software developed for the MATLAB environment. The extracted surface image features are presented in the form of brightness distribution histograms for individual colour components RGB(red, green, and blue) and grayscale Sz. Histogram parameters — average value, standard deviation, maximum value and its position — were calculated. In consequence of conducted studies, it was concluded that an increase in blade heating temperature entailed changes in individual RGB colours and the grayscale (Sz) of their surface images, which indicate the overheating intensity. Full article