As a result of the superior leakage efficiency of brush seals compared to conventional labyrinth seals, compliant contacting filament seals are used to increase the efficiency of jet engines as well as stationary gas and steam turbines. The widespread application of brush seals at different and varying pressure differences combined with variable contacting velocities at the rotor surface requires a profound understanding of the influences of different design parameters on the operational leakage performance. In order to systematically investigate the impact of different design parameters on sealing performance, a new cold air test rig was developed. The new test rig with rotating shaft enables hot-wire anemometry measurements downstream of the seals. These measurements provide insight into the locally resolved flow structure in addition to the integral leakage measurements. For the investigations, one welded and five different clamped brush seals at rotational speeds up to 3000rpm and pressure differences across the seals up to 500kPa are considered. Therefore, the influence of two different designs on the flow through the bristles is presented. For the clamped brush seals, variations of the front and backing plate are investigated. Additionally, the effects of bristle diameter and three different axial inclinations of the bristle pack on the sealing efficiency are shown. Furthermore, initial wear development during the first 30 to 60 hours of brush seal operation at varying experimental conditions is presented and linked to the design parameters. Consequently, the effects of major design aspects on the operational performance of brush seals are examined and presented.

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