Search Results (55)

This study investigates the impact of thermal barrier coatings (TBCs) on the individual contributions of cooling components in impingement-jet combined cooling under low Reynolds number conditions. Using decoupled methods, numerical simulations were conducted for cylindrical, fan-shaped, and conical hole geometries. The results show that without TBCs, the conical hole provides the best cooling performance, while the fan-shaped hole performs the worst. After applying TBCs, the cooling effectiveness of the cylindrical and conical holes remains largely unchanged, but the fan-shaped hole shows significant improvement, with performance comparable to the conical hole. The cylindrical hole keeps a uniform shape, leading to increased velocity and preventing stable film formation. In contrast, the expanding flow passages of the fan-shaped and conical holes promote a gradual decrease in flow velocity, supporting stable film formation and effective thermal protection. Impingement cooling accounts for more than 75% of the overall cooling effectiveness for across hole types. For cylindrical and conical holes, the TBCs primarily enhance in-hole cooling, while for the fan-shaped hole, it increases in-hole cooling effectiveness and shifts film cooling effectiveness from negative to positive, significantly improving its overall contribution. Full article

In the present study, the coaxial waterjet-assisted nanosecond laser drilling of micro-holes in C_f/SiC composites, coupled with nanosecond laser drilling in air for fabricating micro-holes with high aspect ratios, were investigated. The surface morphology, reaction products, and micro-hole shapes were thoroughly examined. The results reveal that, for the coaxial waterjet-assisted nanosecond laser drilling of micro-holes in the C_f/SiC composite, the increasing of waterjet velocity enhances the material removal rate and micro-hole depth, but reduces the micro-hole diameter and taper angle. The coaxial waterjet isolates the laser-ablated region and cools down the corresponding region rapidly, leading to the formation of a mixture of SiC, SiO₂, and Si on the surface. As the coaxial waterjet velocity increases, the morphology of residual surface products changes from a net-like structure to individual spheres. Coaxial waterjet-assisted nanosecond laser drilling, with a waterjet velocity of 9.61 m/s, achieves micro-holes with a good balance between efficiency and quality. For the fabrication of micro-holes with a high aspect ratio in C_f/SiC composites, micro-holes fabricated by nanosecond laser drilling in air exhibit obvious taper features, which should be ascribed to the combined effects of spattering slag, plasma, and energy dissipation. The application of coaxial waterjet-assisted nanosecond laser drilling on micro-holes fabricated by laser drilling in air effectively expands the hole diameter. The fabricated micro-holes have very small taper angles, with clean wall surfaces and almost no reaction products. This approach, combining nanosecond laser drilling in air followed by coaxial waterjet-assisted nanosecond laser drilling, offers a promising technique for fabricating high-quality micro-holes with high aspect ratios in C_f/SiC composites. Full article

This study aims to enhance the understanding of film cooling performance in an actual turbine vane by investigating influencing factors and developing more precise numerical prediction methods. Pressure sensitive paint (PSP) testing and Reynolds-Averaged Navier–Stokes (RANS) simulations were conducted. The findings indicate that the current design blowing ratio of S1 holes (0.89) is too high, resulting in poor film cooling effectiveness. However, the blowing ratios of P3 (0.78) and P4 (0.69) holes are relatively low, suggesting that increasing the coolant flow could improve the film cooling effectiveness. It is not recommended to design an excessively low blowing ratio on the suction surface, as this can lead to poor wall adherence downstream of the film holes. A slight increase in turbulence intensity enhances the film covering effect, particularly on the suction surface. Additionally, a novel superposition method for multirow fan-shaped film cooling holes on an actual turbine vane is proposed, exhibiting better agreement with experimental data. Compared with experimental results, the numerical predictions tend to underestimate the film cooling effectiveness with the examined k-ε-based viscosity turbulence models and Reynolds stress turbulence models, while the SST demonstrates relatively higher accuracy owing to its hybrid k-ω/k-ε formulation that better resolves near-wall physics and separation flows characteristic of turbine cooling configurations. This study contributes to the advancement of turbine vane thermal analysis and design in engineering applications. Full article

Oil shale, an unconventional oil and gas resource, can generate the required hydrocarbons through high-temperature pyrolysis. In situ conversion extraction technology utilizes downhole heaters to directly inject high-temperature heat into the oil shale layer to achieve the effect of oil and gas recovery. For the metal material components of the combustion heaters, the uneven temperature fields experienced during the start of operations, processing, and end of operations can lead to fatigue conditions, such as high-temperature creep, micro-damage, and micro-deformation due to thermal effects. To prevent the occurrence of the aforementioned issues, it is necessary to conduct fatigue life analysis of downhole combustion heaters. By combining actual combustion heater operation experiments with finite element simulation, this paper analyzes the impact of temperature, structure, and stress amplitude on the fatigue life of heaters. The results indicate that the fatigue life of the heaters is most significantly influenced by the metal gaskets, and the higher the exhaust gas temperature, the lower the fatigue life of the heater. Heating operations significantly reduce the fatigue life of the heater, while cooling operations have almost no effect on the fatigue life. Circular-pore metal gaskets have a higher fatigue life than those with a square hole shape. Considering only the thickness of the metal gaskets, the thicker the gasket, the higher the fatigue life. Stress amplitude has the most significant impact on the fatigue life of the heater; when the stress amplitude is doubled, the metal gaskets quickly undergo fatigue damage. Full article

Film cooling can continuously cover a layer of low-temperature gas film on the surface of hot-end components, thereby achieving the effect of isolating high-temperature gas, and can achieve a temperature drop of 600 K. As an advanced and efficient cooling technique, film cooling plays a crucial role in the process of turbine power and efficiency increase, with the key factor influencing its cooling performance being the configuration and arrangement of the film holes. This paper summarizes the design and arrangement of film hole configurations and discusses the potential directions for enhancing film cooling performance. Through analysis, the optimization of film cooling performance is mainly approached from two aspects: first, optimizing the hole configuration, which includes the study of shaped holes, enhancing the cooling performance of cylindrical holes using auxiliary structures, and forming a “reverse kidney-shaped vortex” structure by using a single combined film hole; second, optimizing the arrangement of the cooling holes on the turbine surface to achieve a more uniform and efficient distribution of the cooling film. Future development trends are primarily reflected in the following aspects: designing new, easily manufacturable, high-efficiency film hole configurations and further expanding their stable operating range is an important development direction. It is essential to validate the reverse heat transfer method, assess its applicable range, and, when experimental conditions exceed the applicable range, use related theories to correct its predictive performance. This is key to overcoming the bottleneck in film cooling prediction. It is critical to develop a film hole arrangement guideline that is suitable for various types of film holes and components with temperature differences at the thermal end, to fill the gap in future film cooling optimization design technologies. This study aims to provide new ideas for the optimal design of the cooling system and further improve the power and efficiency of gas turbines. Full article

This study elucidates the underlying formation mechanisms and mitigation strategies for the W-shaped solidification profile in slab continuous casting. Through the development of a multiphysics coupling numerical model, integrated with measured nozzle cooling characteristics in the secondary cooling zone, the effect of steel flow patterns in mold and non-uniform cooling conditions in the secondary cooling zone on solidifying shell evolution is systematically studied. A principal finding is that wide-face shell erosion, induced by both the radial expansion jet and the lower recirculation, constitutes the primary determinant of uneven shell thickness. An increase in the immersion depth and inclination angle of the nozzle side-hole exacerbates the non-uniformity of the solidified shell. Non-uniform cooling in the secondary cooling zone further amplifies the shell thickness differences, culminating in characteristic dumbbell-shaped solidified shell geometry. Strategic implementation of localized enhanced cooling on the wide face in the secondary cooling zone demonstrates significant improvement in shell uniformity, with implementation efficacy contingent upon a critical process window (Segments 1–6). These findings establish mechanistic foundations and deliver practical guidance for minimizing centerline segregation through optimized continuous casting parameter configuration. Full article

The purpose of this article is to inform the reader about the results of an experimental investigation into the appropriate manifold geometry for an air-cooled inverter, which is manufactured from an AlSi10Mg powder material using SLM technology. The best approach is to optimize the part geometry for SLM technology so that the placement of support structures required for model fabrication is eliminated as much as possible. A suitable solution was selected based on the design of the most appropriate cross-sectional shape of the openings with the smallest dimensional accuracy deviation and shape deformation. In the experiment, three test specimens were designed; each of them contained eight holes of different shapes, particularly square, rhombic, and circular, with a given range of sizes. The results of the experimental study can help designers select the optimal design of vents and cavities for the chosen AM technology, e.g., for conformal cooling systems. Full article

This study developed a non-destructive testing (NDT) method using infrared thermography to inspect tubes with holes and slots made by electro-erosion and additive manufacturing. CO₂ was used as a tracer gas to verify the opening and evaluate the flow shape from the holes and slots. To improve the signal contrast, a controlled hot background was used as a reference, and infrared cameras monitored the thermal response to detect flow variations caused by different geometries. The tests included different diameters, pitches, and aspect ratios, comparing results between additive manufacturing and electro-erosion under various conditions. Moreover, a preliminary setup using compressed air and inductive heating was developed to assess hole openings by cooling the piece, aiming to eliminate CO₂ use. The comparison of results, the post-processing analysis of quantitative indices, and specific thermal features enabled a non-destructive evaluation of the holes by using different technologies, providing an assessment of the opening conditions, outlet, geometry, and flow shape. Full article

As the inlet temperature of the gas turbine exceeds the high temperature limit of the blade materials, efficient leading edge cooling technologies are crucial for the further development of gas turbines. Therefore, this paper reviews the research progress on external cooling technology, internal cooling technology, and composite cooling technology for gas turbine rotating blade leading edge cooling. It focuses on the impact of the geometric shape, arrangement, and flow parameters of film cooling holes on external cooling performance, the influence of jet hole design, configuration, crossflow, ribs on internal cooling efficiency, and the characteristics and influencing factors of composite cooling technologies are also discussed. Among the most promising composite cooling techniques, the impingement jet film composite cooling technology and swirl film composite cooling technology stand out. For impingement jet film composite cooling technology, this paper explores the effects of blowing ratio, nozzle parameters, jet hole characteristics, and flow field parameters on the overall cooling performance of the rotating blade leading edge. Impingement jet film composite cooling technology has been shown to significantly improve the cooling performance of the leading edge compared to traditional single cooling techniques. For applications requiring large area cooling or maintaining film integrity, swirl film composite cooling technology not only enhances heat transfer efficiency but also improves the uniformity of heat transfer. The design of swirl nozzles, coolant flow rate, Reynolds number, and jet temperature all have significant effects on the heat transfer efficiency of swirl film composite cooling. To further advance the development of gas turbine rotating blade leading edge cooling technologies, it is recommended to focus on the study of film composite cooling techniques, particularly investigating the effects of various parameters of impingement, swirl on composite cooling performance. Full article

The study of low-speed jets into crossflow is critical to the performance of gas turbines. Film cooling is a method to maintain manageable blade temperatures in turbine sections while increasing turbine inlet temperatures and turbine efficiencies. Initially, cooling holes were cylindrical. Film cooling jets from these discrete round holes were found to be very susceptible to jet liftoff, which reduces surface effectiveness. Shaped holes have become prominent for improved coolant coverage. Fan-shaped holes are the most common design and have shown good improvement over round holes. However, fan-shaped holes introduce additional parameters to the already complex task of modeling cooling effectiveness. Studies of these flows range in hole lengths from those found in actual turbine blades to very long holes with fully developed flow. The flow within the holes themselves is difficult to study as there is limited optical access. However, the flow within the holes has a strong effect on the resulting properties of the jet. This study presents velocity and vorticity fields measured using high-resolution magnetic resonance velocimetry (MRV) to study three different fan-shaped hole geometries at two blowing ratios. Because MRV does not require line of sight, it provides otherwise hard-to-obtain experimental data of the flow within the film cooling hole in addition to the mainflow measurements. By allowing measurement within the cooling hole, MRV shows how a poor choice of diffuser start point and angle can be detrimental to film cooling if overall hole length and cooling flow velocity are not properly accounted for in the design. The downstream effect of these choices on the jet height and counter-rotating vortex pair is also observed. Full article

The prestressed active reinforcement of concrete structures using iron-based shape memory alloys (Fe-SMAs) is investigated in this experimental study through three connecting methods: adhesive–bolted hybrid connection, bolted connection, and adhesively bonded connection by activating at elevated temperatures (heating and cooling) and constraining deformation to generate prestress inside Fe-SMAs, through which compressive stress is generated in the parent concrete structures. In tests, the Fe-SMA is activated at 250 °C using a hot air gun, generating a prestress of 184.6–246 MPa. The experimental results show that local stress concentration in the concrete specimen and Fe-SMA plate around the hole is caused by the bolted connection. The adhesively bonded connection is prone to softening and slip of the structural adhesive during the activation process, thereby reducing the overall recovery force of Fe-SMAs. The adhesive–bolted hybrid connection effectively mitigates the local stress concentration problem of concrete and Fe-SMAs at anchor holes, while avoiding the prestress loss caused by the softening and slip of structural adhesive during elevated-temperature activation, achieving good reinforcement effect. This study on the connection methods of an Fe-SMA for reinforcing concrete structures provides both experimental support and practical guidance for its engineering application, offering new perspectives for future research. Full article

The jet impingement cooling technique is regarded as one of the most effective enhanced heat transfer techniques with a single-phase medium. However, in order to facilitate manufacturing, impingement with a large number of smooth circular hole jets is used in engineering. With the increasing maturity of additive technology, some new special-shaped holes (SSHs) may be used to further improve the cooling efficiency of jet impingement. Secondly, the heat transfer coefficient of the whole jet varies greatly on the impact target surface. The experiments with a large number of single smooth circular hole jets show that the heat transfer coefficient of the impact target surface will form a bell distribution—that is, the Nusselt number has a maximum value near the stagnation region, and then rapidly decreases exponentially in the radial direction away from the stagnation region. The overall surface temperature distribution is very uneven, and the target surface will form an array of cold spots, resulting in a high level of thermal stress, which will greatly weaken the structural strength and life of the equipment. Establishing how to ensure the uniformity of jet impingement cooling has become a new problem to be solved. In order to achieve uniform cooling, special-shaped holes that generate a swirling flow may be a solution. This paper presents a summary of the effects of holes with different geometrical features on the flow field and heat transfer characteristics of jet impingement cooling. In addition, the effect of jet impingement cooling with SSHs in different array methods is compared. The current challenges of jet impingement cooling technology with SSHs are discussed, as well as the prospects for possible future advances. Full article

The main purpose of this investigation was to explore the heat transfer and flow characteristics of aero-foil-shaped fins combined with extended jet holes, specifically focusing on their feasibility in cooling turbine blades. In this study, a comprehensive investigation was carried out by applying impinging jet array cooling (IJAC) on a semi-circular curved surface, which was roughened using aerofoil-shaped fins. Numerical computations were conducted under three different Reynolds numbers (Re) ranging from 5000 to 25,000, while nozzle-to-target surface spacings (S/d) ranged from 0.5 to 8.0. Furthermore, an assessment was made of the impact of different fin arrangements, single-row (L₁), double-row (L₂), and triple-row (L₃), on convective heat transfer. Detailed examinations were performed on area-averaged and local Nusselt (Nu) numbers, flow properties, and the thermal performance criterion (TPC) on finned and smooth target surfaces. The study’s results revealed that the use of aerofoil-shaped fins and the reduction in S/d, along with surface roughening, led to significant increases in the local and area-averaged Nu numbers compared to the conventional IJAC scheme. The most notable heat transfer enhancement was observed at S/d = 0.5 utilizing extended jets and the surface design incorporating aerofoil-shaped fins. Under these specific conditions, the maximum heat transfer enhancement reached 52.81%. Moreover, the investigation also demonstrated that the highest TPC on the finned surface was achieved when S/d = 2.0 for L₂ at Re = 25,000, resulting in a TPC value of 1.12. Furthermore, reducing S/d and mounting aerofoil-shaped fins on the surface yielded a more uniform heat transfer distribution on the relevant surface than IJAC with a smooth surface, ensuring a relatively more uniform heat transfer distribution to minimize the risk of localized overheating. Full article

Increasing the diameter of the drillhole can facilitate drillhole breakage using soundless chemical demolition agents, but it is prone to cause drillhole blowout, resulting in crushing failure. This paper conducted a blowhole prevention test on a large borehole using the internal insertion cooling pipe method (ICBPM) to test the expansion pressure of cooling pipes with different diameters. During this test, a fracture occurred in a hole with a 75 mm inner diameter in the rectangular sandstone specimens with high strength. It was found that utilizing the ICBPM can effectively hinder the development of blowholes. Expansion and blowhole prevention are optimized with a 0.14 mass ratio of the cooling water to demolition agent and a maximum expansion stress of 49.0 MPa. The guiding effect of the minimum resistance line is significant. In repeated tests, all fissures are distributed in a Y-shape on the free surface where the minimum resistance line is located. The acoustic emission signals from statically fractured hard rock increase abruptly before damage, and the development of rock expansion and fracturing can be obtained through strain monitoring. These results suggest that the ICBPM can reduce the expansion time with a strong crushing effect, satisfying the need to process more crushing projects. Full article

Multi-leaf hollow-profiled fiber is a complex-shaped fiber with a hollow structure with at least three leaves arranged outside. In this work, spinning processes for the preparation of multi-leaf hollow-profiled fiber with complex cross-section patterns were proposed. Initially, the characteristics and preparation methods of multi-leaf hollow-profiled fibers were analyzed, and the key technologies for their preparation were studied. Further, micro-hole spinnerets were designed, and the numerical simulations of melt flow in the spinning channel were performed. Then, the preparation of six-leaf hollow profiled fibers was carried out to study the formation of the cross-sections. Finally, as an extension and application, an experimental verification of the melt spinning parameters’ effects on eight-leaf hollow fiber preparation was conducted. From the results of the spinning experiments, it was found that when the volume flow rate of a single hole increased from 2.33 × 10⁻⁸ m³/s to 3.33 × 10⁻⁸ m³/s, the profile degree of the spun fiber increased from 30.93% to a maximum value of 40.99%. Furthermore, when the cooling speed increased from 0.6 m/s to 1 m/s, the profile degree increased from 29.56% to 41.63%. When the initial blowing height increased from 80 mm to 140 mm, the profile degree decreased from 40.99% to 27.13%. When the spinning temperature increased from 285 °C to 290 °C, the profile degree decreased from 40.99% to 38.56%. However, the winding speed had an insignificant effect on the cross-sectional shape of the spun fibers. Moreover, the spun fibers showed good performance and a natural three-dimensional crimp function. Full article