The degradation of gas turbine parts due to aging leads to changes in airfoil shape and often causes performance loss. Although the degradation mechanisms and their effects on performance are understood in general (e.g. it is well known that fouling of compressor airfoils reduces mass flow and efficiency), the first quantitative relationships between specific types of part degradation and performance characteristics have only recently been published. In this paper the degradation of turbine blades with aft-loaded airfoils is considered. The typical deviations of shape were identified based on field experience. The effects of these deviations on turbine performance were assessed using different calculation methods, including 3D Navier-Stokes calculations and methods based on empirical correlations. The effect of blades-length reduction, chord-length reduction, changes in trailing-edge thickness and shape, and variation of stagger angle were analysed. The analysis showed that for aft-loaded airfoils without shrouds, the major influence on turbine performance is the degradation of radial clearances. A simplified engineering procedure allowing estimation of turbine performance loss due to degradation has been developed. This paper demonstrates how this simplified procedure, can be applied to the estimation of turbine recovery potential during a typical engine overhaul.

Tip leakage flow induces high heat transfer to the blade tip and causes significant aerodynamic losses. In this paper, we propose a multi-cavity squealer tip with an additional rib in the squealer cavity. Our study investigated the effects of the rib location and shape on the blade tip heat transfer and the total pressure loss. Experiments were performed in a five-bladed linear cascade using a low speed wind tunnel. The blade chord, pitch, and span length were 126mm, 102.7mm, and 160mm, respectively. The Reynolds number, based on the blade chord and cascade exit velocity, was 2.44×10 5 , and a tip clearance of 1.25% of the blade span was considered. The additional rib was installed in the squealer tip cavity near the leading edge, the mid-chord, and the training edge, respectively. The shape of the rib was also varied from rectangular to triangular in order to minimize the rib surface area exposed to the hot gas. The secondary flow and total pressure loss were measured using a seven-hole probe at one-chord downstream of the blade trailing edge, and the heat transfer coefficient distributions were measured by utilizing the hue-detection based transient liquid crystal technique. Flow measurement results indicated that the proposed multi-cavity tip reduced the total pressure loss. The blade tip heat transfer measurement results showed that the proposed multi-cavity tip was able to reduce the maximum heat transfer region near the cavity floor near the leading edge, but the heat transfer on the second cavity floor increased due to the leakage flow reattachment.

A numerical study is performed to simulate the tip leakage flow and heat transfer on the first stage rotor blade tip of GE-E 3 turbine, which represents a modern gas turbine blade geometry. Calculations consist of the flat blade tip without and with film cooling. For the flat tip without film cooling case, in order to investigate the effect of tip gap clearance on the leakage flow and heat transfer on the blade tip, three different tip gap clearances of 1.0%, 1.5% and 2.5% of the blade span are considered. And to assess the performance of the turbulence models in correctly predicting the blade tip heat transfer, the simulations have been performed by using four different models (the standard k-ε, the RNG k-ε, the standard k-ω and the SST models), and the comparison shows that the standard k-ω model provides the best results. All the calculations of the flat tip without film cooling have been compared and validated with the experimental data of Azad[1] and the predictions of Yang[2]. For the flat tip with film cooling case, three different blowing ratio (M = 0.5, 1.0, and 1.5) have been studied to the influence on the leakage flow in tip gap and the cooling effectiveness on the blade tip. Tip film cooling can largely reduce the overall heat transfer on the tip. And the blowing ratio M = 1.0, the cooling effect for the blade tip is the best.

Most of previous researches of inlet turbulence effects on blade tip have been carried out for low speed situations. Recent work has indicated that for a transonic turbine tip, turbulent diffusion tends to have distinctively different impact on tip heat transfer than for its subsonic counterpart. It is hence of interest to examine how inlet turbulence flow conditioning would affect heat transfer characteristics for a transonic tip. This present work is aimed to identify and understand the effects of both inlet freestream turbulence and end-wall boundary layer on a transonic turbine blade tip aero-thermal performance. Spatially-resolved heat transfer data are obtained at aerodynamic conditions representative of a high-pressure turbine, using the transient infrared thermography technique with the Oxford High-Speed Linear Cascade research facility. With and without turbulence grids, the turbulence levels achieved are 7–9% and 1% respectively. On the blade tip surface, no apparent change in heat transfer was observed with high and low turbulence intensity levels investigated. On the blade suction surface, however, substantially different local heat transfer for the suction side near tip surface have been observed, indicating a strong local dependence of the local vortical flow on the freestream turbulence. These experimentally observed trends have also been confirmed by CFD predictions using Rolls-Royce HYDRA. Further CFD analysis suggests that the level of inflow turbulence alters the balance between the passage vortex associated secondary flow and the OverTL flow. Consequently, enhanced inertia of near wall fluid at a higher inflow turbulence weakens the cross-passage flow. As such, the weaker passage vortex leads the tip leakage vortex to move further into the mid passage, with the less spanwise coverage on the suction surface, as consistently indicated by the heat transfer signature. Different inlet end-wall boundary layer profiles are employed in the HYDRA numerical study. All CFD results indicate the inlet boundary layer thickness has little impact on the heat transfer over the tip surface as well as the pressure side near-tip surface. However, noticeable changes in heat transfer are observed for the suction side near-tip surface. Similar to the freestream turbulence effect, such changes are attributed to the interaction between the passage vortex and the OTL flow.

Design optimization of unshrouded rotor tip cavity of a high pressure turbine stage with low aspect ratio was carried out to maximize the turbine stage efficiency. Cavity shapes were parameterized with 4 design variables including rim thickness, cavity depth, cavity front blend radius and cavity aft blend radius. Initially the CCD method was utilized for sampling experimental points and the Kriging method was chosen to construct an approximation model. The optimum points derived from the approximation model were assessed by CFD analyses to verify the approximation model. The approximation model was refined repeatedly by adding more experiment points to minimize difference of CFD result and predicted value from the approximation model at the optimum point. The optimization result showed that there is an optimum ratio of cavity depth to tip clearance height, while the optimum design suggests cavity front blend radius and cavity aft blend radius be as small as possible within the design range. As the tip clearance height increases, the optimized tip cavity depth increases. However, the rim thickness has little effect on the optimum tip cavity depth. Without the tip cavity, leakage flow at fore part of the blade suction surface develops large vortex flow from the starting point of the unguided turning region due to adverse pressure gradient. The tip cavity prevents the early leakage flow from flow to the suction surface, which suppresses the leakage flow dissipation to the loss. It results in efficiency improvement. The effect of the tip cavity on the efficiency increases at the larger tip clearance. On the other hand, the cavity rim thickness effect on the efficiency becomes noticeable when the tip cavity depth is over than the optimum value. The rim thickness effect mainly appears on the tip leakage flow after the blade throat. The leaked flow after the blade throat generates a high loss region near the blade tip, especially when the rim thickness is small. The loss from the thick tip cavity rim gradually increases as the tip clearance increases. However, the rim thickness effect is most sensitive when the tip clearance is small. The loss generation mechanism due to the rim thickness is totally different to the tip cavity depth effects on the total pressure loss.

Most of the current understanding of tip leakage flows has been derived from detailed cascade experiments. However, the cascade model is inherently approximate since it is difficult to simulate the boundary conditions present in a real machine, particularly the secondary flows convecting from the upstream stator row and the relative motion of the casing and blade. This problem is further complicated when considering the high pressure turbine rotors of aero engines, where the high Mach numbers must also be matched in order to correctly model the aerodynamics and heat transfer. More realistic tests can be performed on high-speed turbines, but the experimental fidelity and resolution achievable in such set-ups is limited. In order to examine the differences between cascade models and real-engine behavior, the influence of boundary conditions on the tip leakage flow in an unshrouded high pressure turbine rotor is investigated using RANS calculations. This study examines the influence of the rotor inlet condition and relative casing motion. A baseline calculation with a simplified inlet condition and no relative endwall motion exhibits similar behavior to cascade studies. Only minor changes to the leakage flow are induced by introducing either a more realistic inlet condition or relative casing motion. However when both of these conditions are applied simultaneously the pattern of leakage flow is very different, with ingestion of flow over much of the early suction surface. The paper explores the physical processes driving this change and the impact on leakage losses and modeling requirements.

In this paper we use direct numerical simulation to investigate the unsteady flow over a model turbine blade-tip at engine scale Reynolds and Mach numbers. The DNS is performed with a new in-house multi-block structured compressible Navier-Stokes solver purposely developed for exploiting high-performance computing systems. The particular case of a transonic tip flow is studied since previous work has suggested compressibility has an important influence on the turbulent nature of the separation bubble at the inlet to the gap and subsequent flow reattachment. The effects of free-stream turbulence, cross-flow and pressure-side boundary-layer on the tip flow aerodynamics and heat transfer are investigated. For ‘clean’ in-flow cases we find that even at engine scale Reynolds numbers the tip flow is intermittent in nature (neither laminar nor fully turbulent). The breakdown to turbulence occurs through the development of spanwise modes with wavelengths around 25% of the gap height. Cross-flows of 25% of the streamwise gap exit velocity are found to increase the stability of the tip flow, and to significantly reduce the turbulence production in the separation bubble. This is predicted through in-house linear stability analysis, and confirmed by the DNS. For the case when the inlet flow has free-stream turbulence, viscous dissipation and the rapid acceleration of the flow at the inlet to the tip-gap causes significant distortion of the vorticity field and reductions of turbulence intensity as the flow enters the tip gap. This means that only very high turbulence levels at the inlet to the computational domain significantly affect the tip heat transfer. The DNS results are compared with RANS predictions using the Spalart-Allmaras and k – ω SST turbulence models. The RANS and DNS predictions give similar qualitative features for the tip flow, but the size and shape of the inlet separation bubble and shock positions differ noticeably. The RANS predictions are particularly insensitive to free-stream turbulence.

Shroudless turbine designs offer the advantages of weight reduction and lower mechanical loads on the one hand but bear challenges as high gap sensitivity and high temperatures of the static parts on the other hand. In the last years, a lot of work was carried out in order to develop a sealing system for a shroudless design consisting of an abrasive blade tip coating and an abradable segment coating addressing all the requirements defined. Aside from being abradable, the segment coatings have to be mechanically stable, withstand high thermo-mechanical loadings and have to work for thicknesses larger than 1 mm. Due to the limited temperature capability of the currently used segment coating material yttria-stabilised zirconia, which combines advantageously a suitable thermal conductivity with a high thermal expansion coefficient, new ceramic materials for the segment coating had to be developed. A very promising sealing system combines an abrasive blade tip coating with an yttria-stabilised zirconia / magnesia alumina spinel double-layer abradable coating system with a 3D interface structure between the bond coat and the ceramic coatings. The present work gives an overview of the development and the performance of this sealing system.

The present investigation analyzes the effect of the extension of the radial gap on the heat transfer at the blade tip and the casing within a high-pressure turbine stage of an aircraft engine. Due to the rotation and the interaction of the adjacent blade-rows, the flow field in the tip region of an unshrouded rotor-blade is characterized by a high level of unsteadiness. Furthermore, the casing is exposed to the passing blade-gap and corresponding changes in the velocity-profile, the resulting near-wall velocity-gradients, and the resulting changes in heat transfer. In order to account for these effects, time-resolved RANS computations of three different radial gaps are performed and evaluated. The present analysis shows an influence of the radial gap on the characteristics of the steady and unsteady heat transfer and a correlation with the size of the tip-clearance vortex can be shown.

Blade shrouding gives an opportunity to increase the HPT (high pressure turbine) first stage efficiency by 2–3 %. However, if high gas temperature and high circumferential velocity are at the stage, shrouding can be problematic due to load increasing at blade/disk attachment and high temperature of the shroud itself. To make blade/disk attachment more reliable the shroud axial width has to be decreased by increasing a relative pitch of airfoil cascades t ( t = t / b , where t – pitch, b – chord) at the blade tip span. According to experience for a flow with β 1 = 50 – 85°, M 2 = 0.8 – 1, and Re = (0.8 – 1)•10 6 high efficient cascades with t = 0.93 – 1.05 can be designed. Application of such a profiling for GTE (gas turbine engine) turbine is demonstrated here. In the turbine meridian flow path the blade was drastically tapered to the tip (tip width was 53 % of the mean width and 46 % of the hub width). To lighten the blade a partial shrouding can be also applied. Model turbine tests showed that local cuts at the front shroud area and the aft shroud area at the airfoil pressure side influenced the efficiency weakly. Required shroud temperature is provided with a cooling. The aircraft turbine with a governed cooling system and a radial clearance control is an example here. In this case the shroud had 3 labyrinth ribs. The shrouding decreased radial clearance by 0.8 mm at main design modes that increased efficiency by ∼ 1.5 %. To cool down the shroud the air downstream the compressor was fed into the cavity behind the front labyrinth rib. At maximal mode with full cooling the relative coolant mass flow (to the compressor mass flow) was m c = 1.3 % and gas leakages through the labyrinth were 0.2 %. It gave acceptable mixed temperature of 530°C in the cavity over the shroud. At cruise high altitude mode and a lower gas temperature and partial cooling with m c = 0.4 % and gas leakages of 0.1 % the mixed temperature also did not exceed 530°C over the shroud. The assessment with taking into account changes of the clearance, the coolant mass flow, and gas leakages showed that the shrouding provided the engine economy improvement by 0.7 – 0.9 % for both modes. For GTPU (gas turbine power unit) the first blade shrouding can be more complicated. However, even the slight turbine efficiency increase provides considerable profits due to GTPU huge power output and long term running. So, when GTE and GTPU designing starts, it is reasonable to consider the turbine first blade shrouding. Here the integral evaluation criterion, which includes the assessment of a possible income from the unit full life cycle running, has to be applied.

Currently, the aerodynamics and heat transfer over a turbine blade tip tend to be analyzed separately with the assumption that the wall thermal boundary conditions do not affect the Over-Tip-Leakage (OTL) flow field. There are some existing correlations for correcting the wall temperature effect on heat transfer. But they were mainly developed to account for the temperature dependence on fluid properties, and are inherently limited by the empirical nature. The questions arise with regard to: is the OTL aerodynamics significantly affected by the wall thermal condition? And if it is, how can we count this effect consistently in turbine blade tip design and analysis using modern CFD methods? In the present study, the problem has been examined for typical HP turbine blade tip configurations. An extensively developed RANS code (HYDRA) is employed and validated against the experimental data from a high speed linear cascade testing rig. The numerical analysis reveals that the wall-gas temperature ratio could greatly affect the transonic OTL flow field and there is a strong two-way coupling between aerodynamics and heat transfer. The feedbacks of the thermal boundary condition to aerodynamics behave differently at different flow regimes over the tip, clearly indicating a highly localized dependence of the convective heat transfer coefficient (HTC) upon wall temperatures. This implies that to use HTC for blade metal temperature predictions without resorting a fully conjugate solution, the temperature dependence needs to be corrected locally. A nonlinear correction approach has been adopted in the present work, and the results demonstrate its effectiveness for the transonic turbine tip configurations studied.

The increase of new gas turbine’s efficiency is connected with further rise of turbine inlet temperature and sometimes as well pressure. In these conditions, first cooled turbine stages of a gas turbine engine usually consist of freestanding airfoils, which do not use an integrated shroud, to avoid risk of shroud overheating. In order to better control the radial gap leakage flow between the rotating blade tip and turbine casing, special design features of the airfoil tip need to be considered in the design process to meet the best possible stage performance. In the general engineering practice, a blade tip squealer provides opportunities to control tip clearance loss. In this paper several simplified types of the tip squealer design are investigated to determine the most effective loss control. At this stage of the investigation, blade tip cooling was not taken into account, but aerodynamic effects were analysed in detail. Based on the most common designs of the blade tip in the literature, four geometry types were investigated: (i) a flat tip design as the reference baseline solution, (ii) full tip squealer, (iii) partial squealer along the pressure side (PS) wall with a cut-out at the pressure side near the trailing edge (TE) and (iv) partial squealer along the suction side (SS) wall with a cut-out at the suction side near TE. All these cases have been compared among each other for two relative radial gaps (gap to blade height) of 0.6% and 1.36%. The flow calculations were done with a full 3D Navier-Stokes CFD code. For the flat tip and for full squealer designs, numerical results were validated against well-known experimental data measured on the GE-E 3 blade cascade test rig found in the open literature. By using the 3D numerical data, the special attention was considered to confirm reliability and predictive credibility of the blade tip flow obtained from the analytical model. The obtained loss values and flow details were compared for all studied cases, providing insight into turbine stage aerodynamics with respect to minimal and maximal radial clearance.

One of the key factors ensuring gas turbine engines (GTE) competitiveness is improvement of life, reliability and fuel efficiency. However fuel efficiency improvement and the required increase of turbine inlet gas temperature (T* g ) can result in gas turbine engine life reduction because of hot path components structural properties deterioration. Considering circumferential nonuniformity, local gas temperature T* g can reach 2500 K. Under these conditions the largest attention at designing is paid to reliable cooling of turbine vanes and blades. At present in design practice and scientific publications comparatively little attention is paid to detailed study of turbine split rings thermal condition. At the same time the experience of modern GTE operation shows high possibility of defects occurrence in turbine 1 st stage split ring. This work objective is to perform conjugate numerical simulation (gas dynamics + heat transfer) of thermal condition for the turbine 1 st stage split ring in a modern GTE. This research main task is to determine the split ring thermal condition by defining the conjugate gas dynamics and heat transfer result in ANSYS CFX 13.0 package. The research subject is the turbine 1 st stage split ring. The split ring was simulated together with the cavity of cooling air supply from vanes through the case. Besides turbine 1 st stage vanes and blades have been simulated. Patterns of total temperature (T* Max = 2000 °C) and pressure and turbulence level at vanes inlet (19.2 %) have been defined based on results of calculating the 1 st stage vanes together with the combustor. The obtained results of numerical simulation are well coherent with various experimental studies (measurements of static pressure and temperature in supply cavity, metallography). Based on the obtained performance of the split ring cooling system and its thermal condition, the split ring design has been considerably modified (one supply cavity has been split into separate cavities, the number and arrangement of perforation holes have been changed etc.). All these made it possible to reduce considerably (by 40…50 °C) the split ring temperature comparing with the initial design. The design practice has been added with the methods which make it possible to define thermal condition of GTE turbine components by conjugating gas dynamics and heat transfer problems and this fact will allow to improve the designing level substantially and to consider the influence of different factors on aerodynamics and thermal state of turbine components in an integrated programming and computing suite.

In terms of efficiency improvement many methods for reducing the blade tip-leakage mass flow rate have been proposed. Some of these methods are based on increasing the flow resistance with aid of geometrical modifications of the blade tip (squealers, winglets, shrouded blades, etc.) whereas other methods take advantage of aerodynamical resistance with passive tip-injection as an example. The objective of this paper is a combination of both methods in order to achieve higher reduction in tip-leakage mass flow rate. In the first part of this work necessary characteristic parameters of modern low pressure turbine blades in aircraft gas turbines are estimated. These parameters are taken into consideration to calculate the range of physical quantities influencing tip-leakage flow. Subsequently a two dimensional flow model is obtained with the so called discharge coefficient as the ratio of the actual tip gap mass flow rate to its highest possible value. The investigations are based on dimensionless calculations. In the end the results obtained from dimensionless 2D CFD-simulations are presented and compared with the analytical results. This leads to conclusions regarding the impact of various parameters on the effectiveness of the passive tip-injection.

Abradable/abrasive sealing systems are currently used in gas turbines to reduce the blade tip gas leakage and consequently improve the turbine efficiency. The coatings selection is directly related to the section in which they are used. Seal systems for hot gas paths are primarily required to withstand high temperature. The abradable coating should be easily removed by the tip blade without causing significant blade wear, whereas the blades should have sufficient cutting capabilities. Durability properties, such as erosion resistance, are also required. Owing to their temperature capabilities, porous ceramic coatings are successfully used as abradable coatings. Although they are characterized by good abradability properties, their resistance to environmental attacks, such as solid particle erosion, is limited by the porous microstructure which negatively affects their service life. It is apparent that durability and abradability are the main targets to be simultaneously achieved for ensuring longer service life and improved efficiency. The present work is aimed at developing new abradable/abrasive coatings pairs able to ensure both the durability performances of the coatings and good abradability properties. Three ceramic abradable coatings with DVC and porous microstructure have been studied. The down-selection process has been carried out by considering the microstructure, the hardness, the tensile adhesion strength, the erosion resistance, and the furnace cycle test resistance. A composite coating made by NiCoCrAlY matrix containing abrasive grits applied by electrolytic process was selected as abrasive material system. The abrasive grits (patent application in process by GE Oil&Gas) consists of a mixture of ceramic particles. These grits ensure both short-term cutting capability and thermal stability, assuring the clearance maintenance over time. The abradability of the seal system was assessed by a properly designed test, namely Rub Rig test, which simulates the blade incursion in the abradable coating. Surface patterns on abradable coating were also considered to further enhance the abradability. Engine tests are foreseen for assessing the service behavior of this seal system.

Tip leakage flows in unshrouded high speed turbines cause large aerodynamic penalties, induce significant thermal loads and give rise to intense thermal stresses onto the blade tip and casing endwalls. In the pursuit of superior engine reliability and efficiency, the turbine blade tip design is of paramount importance and still poses an exceptional challenge to turbine designers. The ever-increasing rotational speeds and pressure loadings tend to accelerate the tip flow velocities beyond the transonic regime. Overtip supersonic flows are characterized by complex flow patterns, which determine the heat transfer signature. Hence, the physics of the overtip flow structures and the influence of the geometrical parameters on the overtip flow require further understanding to develop innovative tip designs. Conventional blade tip shapes are not adequate for such high speed flows and hence, potential for enhanced performances lays in appropriate tip shaping. The present research aims to quantify the prospective gain offered by a fully contoured blade tip shape against conventional geometries such as a flat and squealer tip. A detailed numerical study was conducted on a modern transonic turbine rotor blade (Reynolds number is 5.5 × 10 5 , relative exit Mach number is 0.9) by means of three-dimensional Reynolds-Averaged Navier-Stokes calculations. The novel contoured tip geometry was designed based on a 2D tip shape optimization in which only the upper 2% of the blade span was modified. This study yields a deeper insight into the application of blade tip carving in high speed turbines and provides guidelines for future tip designs with enhanced aerothermal performances.

Tip-leakage losses can contribute up to one third of the overall losses in unshrouded axial turbine blades. A passive tip-leakage flow control method is used to reduce the tip-leakage loss. Taking into account a modified discharge coefficient model, an inclination of the injection against the tip-leakage flow direction is said to have an even better effect on reducing the tip-leakage loss. To prove the effect, linear cascade measurements have been carried out at three different gap widths from 0.85% to 2.50% chord length. The used geometry is an up-scaled turbine blade tip cross section with weak turning. A single blade is fitted with an injection channel which is inclined by 45° against the tip-leakage flow direction. The flow field of the modified blade was measured 0.31 axial chord length downstream of the cascade using a pneumatic five-hole probe. The tip-leakage loss is reduced by passive tip-injection and further by inclined injection. The reduction can be significant at small gap widths. Detailed results are presented for a gap width of 1.40% chord length.