For the thermal design of combustion chambers and turbine blades in jet engines, a detailed knowledge of the combustion and of the heat loads to the walls is necessary. In general, high operating temperatures and reduced combustor size are striven for in order to increase engine efficiency and reduce weight. Consequently, the components are exposed to temperatures above the melting point of the materials and there is a growing risk of incomplete combustion within the combustion chambers. To study these effects, we setup a new test bench for fundamental investigation of chemical near-wall reactions at atmospheric pressure. First results of gaseous, nonpremixed near-wall CH 4 /air and H 2 /air flames are presented. Optical methods such as two-line laser-induced fluorescence thermometry and OH* chemiluminescence were applied. Further, the heat release to the wall was determined by means of inverse heat conduction calculation using the data of implemented thermocouples.

In this work, the growth regime of combustion instability was studied by analyzing 10 kHz OH planar laser induced fluorescence (PLIF) images through a combination of dynamic mode decomposition (DMD) and spectral proper orthogonal decomposition (SPOD) methods. Combustion instabilities were induced in a mesoscale burner array through an external speaker at an imposed perturbation frequency of 210 Hz. During the transient onset of combustion instabilities, 10 kHz OH PLIF imaging was employed to capture spatially and temporally resolved flame images. Increased acoustic perturbations prevented flame reignition in the central recirculation zone and eventually led to the flame being extinguished inwards from the outer burner array elements. Coherent modes and their growth rates were obtained from DMD spectral analyses of high-speed OH PLIF images. Positive growth rates were observed at the forcing frequency during the growth regime. Coherent structures, closely associated with thermoacoustic instability, were extracted using an appropriate SPOD filter operation to identify mode structures that correlate to physical phenomena such as shear layer instability and flame response to longitudinal acoustic forcing. Overall, a combination of DMD and SPOD was shown to be effective at analyzing the onset and propagation of combustion instabilities, particularly under transient burner operations.

Due to several recent developments in lasers and optics, laser igniters can now be designed to be (i) compact so as to have the same footprint as a standard spark plug, (ii) have low power draw, usually less than 50 Watts, and (iii) have vibration and temperature resistance at levels typical of reciprocating engines. Primary advantages of these laser igniters remain (i) extension of lean or dilution limits for ignition of combustible mixtures, and (ii) improved ignition at higher pressures. Recently, tests performed in a 350 kW 6-cylinder stationary natural gas reciprocating engine retrofitted with these igniters showed an extension of the operational envelope to yield efficiency improvements of the order of 2.6% points while being compliant with the mandated emission regulations. Even though laser igniters offer promise, fouling of the final optical element that introduces the laser into the combustion chamber is of concern. After performing a thorough literature search, a test plan was devised to evaluate various fouling mitigation strategies. The final approach that was used is a combination of three strategies and helped sustain an optical transmissivity exceeding 98% even after 1500 hrs. of continuous engine operation at 2400 rpm. Based on the observed trend in transmissivity, it now appears that laser igniters can last up to 6000 hrs. of continuous engine operation in a stationary engine running at 1800 rpm.

Metal shafts are indispensable components in mobility, energy, and mechanical engineering. In such applications, the shafts need to withstand severe mechanical loads, friction, high temperature, or corrosive media. This is why shafts are often completely made of high-performance alloys. From a technical point of view, coating an inexpensive base shaft with a thin layer of high-performance material is mostly sufficient to ensure its functionality. Adding functional parts such as shoulders or bearing seats by additive manufacturing instead of creating them by subtractive manufacturing is an advantageous approach to increase flexibility and material efficiency. Reliable and economic Additive Manufacturing and coating processes need to be developed further, and laser-based processes such as wire-based laser metal deposition (LMD-w) offer high potential to accomplish this. They can generate a stable metallurgical bond between the base material and the cladding or the added feature without excessively heating the work piece. Due to their low build-up rate, however, LMD processes are not economically competitive with high-speed subtractive technologies such as drilling or turning, which are predominately used for shaft production. Motivated by this challenge, we present an alternative approach that increases the deposition rate for laser-based shaft cladding. Instead of adding the filler wire continuously, wire coils are wound and preplaced on the shaft. In a second step, laser processing while rotating the part generates a metallurgical bond between the wire and the substrate. In this study, several solid and flux-cored wires were analyzed regarding their suitability for this two-step coil winding and LMD process. The results from LMD experiments give an overview of the resulting surface state and of the welded joint quality after deposition. Metallographic cross-sections show low porosity of the deposited layers and small heat-affected zones in the base shaft. Thanks to its good scalability, this innovative two-step process can help strongly increase the build-up rate compared to classic LMD-w.

Particle image velocimetry (PIV) is a well-established technique for determining the flow direction and velocity magnitude of complex flows. This paper presents a methodology for executing this nonintrusive measurement technique to study a scaled-up turbine vane geometry within an annular cascade at engine-relevant conditions. Custom optical tools such as laser delivery probes and imaging inserts were manufactured to mitigate the difficult optical access of the test section and perform planar PIV. With the use of a burst-mode Nd: YAG laser and Photron FASTCAM camera, the frame straddling technique is implemented to enable short time intervals for the collection of image pairs and velocity fields at 10 kHz. Furthermore, custom image processing tools were developed to optimize the contrast and intensity balance of each image pair to maximize particle number and uniformity while removing scattering and background noise. The preprocessing strategies significantly improve the vector yield under challenging alignment, seeding, and illumination conditions. With the optical and software tools developed, planar PIV was conducted in the passage of a high-pressure stator row, at midspan, in an annular cascade. Different Mach and Reynolds number operating conditions were achieved by modifying the temperature and mass flow. With careful spatial calibration, the resultant velocity vector fields are compared with Reynolds-averaged-Navier–Stokes (RANS) simulations of the vane passage with the same geometry and flow conditions. Uncertainty analysis of the experimental results is also presented and discussed, along with prospects for further improvements.

Increasingly stringent regulations are imposed on nitrogen oxides emissions due to their numerous negative impacts on human health and the environment. Accurate, experimentally validated thermochemical models are required for the development of the next generation of combustors. This paper presents a series of experiments performed in lean, premixed, laminar, jet-wall stagnation flames at pressures of 2, 4, 8, and 16 atm. To target postflame temperatures relevant to gas turbine engines, the stoichiometry of the nonpreheated methane–air mixture is adjusted to an equivalence ratio of 0.7. One-dimensional (1D) profiles of temperature and NO mole fraction are measured via laser-induced fluorescence (LIF) thermometry and NO-LIF, respectively, to complement previously published flame speed data (Versailles et al., 2018, “Measurements of the Reactivity of Premixed, Stagnation, Methane-Air Flames at Gas Turbine Relevant Pressures,” ASME. J. Eng. Gas Turbines Power, 141(1), p. 011027). The results reveal that, as the pressure increases, the maximum postflame temperature stays relatively stable, and the concentration of NO produced through the flame front remains constant within uncertainty. Seven thermochemical models, selected for their widespread usage or recent date of publication, are validated against the experimental data. While all mechanisms accurately predict the postflame temperature, thanks to consistent thermodynamic parameters, important disagreements are observed in the NO concentration profiles, which highlights the need to carefully select the models used as design tools. The lack of pressure dependence of NO formation that many models fail to capture is numerically investigated via sensitivity and reaction path analyses applied to the solution of flame simulations. The termolecular reaction H + O 2 ( + M ) ↔ HO 2 ( + M ) is shown to hinder the production of atomic oxygen and to consume hydrogen radicals at higher pressures, which inhibits the formation of nitric oxide through the N 2 O pathway.

Shockless explosion combustor (SEC) is a promising concept for implementing pressure gain combustion into a conventional gas turbine cycle. This concept aims for a quasi-homogeneous auto-ignition that induces a moderate rise in pressure. Since the ignition is not triggered by an external source but driven primarily by chemical kinetics, the homogeneity of the auto-ignition is very sensitive to local perturbations in equivalence ratio, temperature, and pressure that produce undesired local premature ignition. Therefore, the precise injection of a well-defined fuel profile into a convecting air flow is crucial to ensure a quasi-homogeneous ignition of the entire mixture. The objective of this work is to demonstrate that the injected fuel profile is preserved throughout the entire measurement section. For this, two different control trajectories are investigated. Optical measurement techniques are used to illustrate the effect of turbulent transport and dispersion caused by boundary layer effects on the fuel concentration profile. Results from line-of-sight measurements by tunable diode laser absorption spectroscopy indicate that the transport of the fuel-air mixture is dominated by turbulent diffusion. However, comparisons to numerical calculations reveal the effect of dispersion toward the bounds of the fuel concentration profile. The spatially resolved distributions of the fuel concentration inside the combustor gained from acetone planar laser induced fluorescence (PLIF) replicates a typical velocity distribution of turbulent pipe flow in radial direction visualizing boundary layer effects. Comparing both methods provides deep insights into the transport processes that have an impact on the operation of the SEC.

Modern high-efficiency engines utilize direct injection for charge preparation at extremely high pressures. At these conditions, the scales of atomization become challenging to measure, as primary breakup occurs on the micrometer and nanosecond scales. As such, fuel sprays at these conditions have proven difficult to study via direct imaging. While high-speed cameras now exist that can shutter at tens to hundreds of nanoseconds, and long-range microscopes can be coupled to these cameras to provide high-resolution images, the resolving power of these systems is typically limited by pixel size and field of view (FOV). The large pixel sizes make the realization of the diffraction-limited optical resolution quite challenging. On the other hand, limited data throughput under high repetition rate operation limits the FOV due to reduced sensor area. Therefore, a novel measurement technique is critical to study fuel spray formation at engine-relevant conditions. In this work, we demonstrate a new high-resolution imaging technique, spectral microscopy, which aims to realize diffraction-limited imaging at effective framerates sufficient for capturing primary breakup in engine-relevant sprays. A spectral microscopy system utilizing a consumer-grade DSLR allows for significantly wider FOV with improved resolving power compared to high-speed cameras. Temporal shuttering is accomplished via separate and independently triggered back illumination sources, with wavelengths selected to overlap with the detection bands of the camera sensor's RGB filter array. The RGB detection channels act as filters to capture independently timed red, green, and blue light pulses, enabling the capture of a three consecutive images at effective framerates exceeding 20 × 10 6 fps. To optimize system performance, a backlit illumination system is designed to maximize light throughput, a multilens setup is created, and an image-processing algorithm is demonstrated that formulates a three-frame image from the camera sensor. The system capabilities are then demonstrated by imaging engine relevant diesel sprays. The spectral microscopy system detailed in this paper allows for micron-scale feature recognition at framerates exceeding 20 × 10 6 fps, thus expanding the capability for experimental research on primary breakup in fuel sprays for modern direct-injection engines.

A detailed investigation on flame structures and stabilization mechanisms of confined high momentum jet flames by one-dimensional (1D)-laser Raman measurements is presented. The flames were operated with natural gas (NG) at gas turbine relevant conditions in an optically accessible high-pressure test rig. The generic burner represents a full scale single nozzle of a high temperature FLOX ® gas turbine combustor including a pilot stage. 1D-laser Raman measurements were performed on both an unpiloted and a piloted flame and evaluated on a single shot basis revealing the thermochemical states from unburned inflow conditions to burned hot gas in terms of average and statistical values of the major species concentrations, the mixture fraction and the temperature. The results show a distinct difference in the flame stabilization mechanism between the unpiloted and the piloted case. The former is apparently driven by strong mixing of fresh unburned gas and recirculated hot burned gas that eventually causes autoignition. The piloted flame is stabilized by the pilot stage followed by turbulent flame propagation. The findings help to understand the underlying combustion mechanisms and to further develop gas turbine burners following the FLOX concept.

Recent work by the authors and others has uncovered the need for further chemical kinetic-related modeling and experiments, specifically for NO x kinetics at engine conditions. In particular, data on CH formation at realistic combustion conditions are needed for further refinement of the prompt-NO x kinetics. To this end, a series of shock-tube experiments to obtain CH concentration time histories at elevated temperatures was performed behind reflected shock waves at the Aerospace Corporation using a tunable laser. This Ti-Sapphire laser was operated in the near infrared at about 854 nm; blue light at 426.9 nm was obtained using an external, frequency-doubling crystal. The resulting light was used in a differential absorption setup with common-mode rejection to measure CH time histories. New measurements in CH 4 –C 2 H 6 –O 2 mixtures highly diluted in argon were performed at temperatures between 1890 K and 2719 K. These new data are compared to several modern, detailed chemical kinetics mechanisms with updated NO x submechanisms. Sensitivity and rate of production analyses at the shock-tube conditions along with a gas turbine model are used to elucidate the current state of affairs in CH prediction by the literature models and its effect on NO x production, particularly through the prompt mechanism. A brief discussion of the chemical kinetics for an important reaction in the production of CH is also presented to emphasize the need for further study and refinement of reactions leading to CH production.

Premixed or partially premixed swirling flames are widely used in gas turbine applications because of their compactness, high ignition efficiency, low NO x emissions and flame stability. A typical annular combustor consists of about twenty swirling flames, which interact (directly or indirectly) with their immediate neighbors even during stable operation. These interactions significantly alter the flow and flame topologies thereby bringing in some discrepancies between the single nozzle (SN) and multinozzle (MN), ignition, emission, pattern factor and flame transfer function (FTF) characteristics. For example, in MN configurations, application of a model based on SN FTF data could lead to erroneous conclusions. Due to the complexities involved in this problem in terms of size, thermal power, cost, optical accessibility etc., a limited amount of experimental studies has been reported, that too on scaled down models with reduced number of nozzles. Here, we present a detailed experimental study on the behavior of three interacting swirl premixed flames, arranged in-line in an optically accessible hollow cuboid test section, which closely resembles a three-cup sector of an annular gas turbine combustor with very large radius. Multiple configurations with various combinations of swirl levels between the adjacent nozzles and the associated flame and flow topologies have been studied. Spatio-temporal information of the heat release rate obtained from OH * chemiluminescence imaging is used along with the acoustic pressure signatures to compute the Rayleigh index (RI) so as to identify the regions within the flame that pumps energy into the self-excited thermoacoustic instability modes. It is found that the structure of the flame–flame interaction regions plays a dominant role in the resulting thermoacoustic instability. To resolve the flow and reactive species distributions in the interacting flames, two-dimensional (2D), three component stereoscopic particle image velocimetry (SPIV) and planar laser-induced fluorescence (PLIF) of hydroxyl radical is applied to all the test conditions. Significant differences in the flow structures among the different configurations were observed. Simultaneous OH-PLIF and SPIV techniques were also utilized to track the flame front, from which the curvature and stretch rates were computed. Flame surface density (FSD) which is defined as the mean surface area of the reaction zone per unit volume, is also computed for all the test cases. These measurements and analyses elucidate the structure of the interaction regions, their unique characteristics, and possible role in thermoacoustic instability.

New laminar flame speed experiments have been collected for two alternative liquid fuels. Understanding the combustion characteristics of these synthetic fuels is an important step in developing new chemical kinetics mechanisms that can be applied to real fuels. Included in this study are two synthetic Jet fuels: Syntroleum S-8 and Shell GTL. The precise composition of these fuels is known to change from sample to sample. Since these are low-vapor pressure fuels, there are additional uncertainties in their introduction into gas-phase mixtures, leading to uncertainty in the mixture equivalence ratio. An in-situ laser absorption technique was implemented to verify the procedure for filling the vessel and to minimize and quantify the uncertainty in the experimental equivalence ratio. The diagnostic utilized a 3.39- μ m HeNe laser in conjunction with Beer's law. The resulting spherically expanding, laminar flame experiments were conducted over a range of equivalence ratios from φ = 0.7 to φ = 1.5 at initial conditions of 1 atm and 403 K in the high-temperature, high-pressure (HTHP) constant-volume vessel at Texas A&M University. The experimental results show that both fuels have similar flame speeds with a peak value just under 60 cm/s. However, it is shown that when comparing the results from different datasets for these real fuels, equivalence ratio may not be the best parameter to use. Fuel mole fraction may be a better parameter to use as it is independent of the average fuel molecule or fuel surrogate used to calculate equivalence ratio in these real fuel/air mixtures.

Higher shares of variable renewable generation have already raised the demand for energy storage and network services in the power sector. As this trend is expected to continue, the combination of these services in a large scale will be imperative toward a carbon-free power sector. A very promising way to perform this task without any additional emissions is through stoichiometric combustion of the electrolysis products (H 2 and O 2 ) in steam and the injection of the generated steam in a conventional steam cycle. However, this can be done only if the product steam has only traces of the two reactants in it, in order to avoid damage of downstream components. The amount of residual gas in the product steam is a direct function of the combustion efficiency. This work analyzes the combustion efficiency of a H 2 /O 2 combustor under steam dilution. As the product gas of such a combustor is primarily steam, the intended efficiency measurement is very challenging and cannot be performed with conventional methods. Instead, an in situ measurement of oxygen and hydrogen is applied. The respective diagnostics and challenges are presented along with the combustion efficiency results. Moreover, a combustor design study is carried out and different flame types (jet and swirl-stabilized flames) are compared. The initial results demonstrate that steam-diluted H 2 /O 2 combustion can achieve an efficiency close to 100%.

The National Jet Fuel Combustion Program (NJFCP) is an initiative being led by the Office of Environment & Energy at the FAA, to streamline the ASTM jet fuels certification process for alternative aviation fuels. To accomplish this, the program has identified specific applied research tasks in several areas. The National Research Council of Canada (NRC) is contributing to the NJFCP in the areas of sprays and atomization and high altitude engine performance. This paper describes work pertaining to atomization tests using a reference injection system. The work involves characterization of the injection nozzle, comparison of sprays and atomization quality of various conventional and alternative fuels, and uses the experimental data to validate spray correlations. The paper also briefly explores the application viability of a new diagnostic system that has the potential to reduce test time in characterizing sprays. Measurements were made from ambient up to 10 bar pressures in NRC's High Pressure Spray Facility using optical diagnostics including laser diffraction, phase Doppler anemometry (PDA), LIF/Mie imaging and laser sheet imaging to assess differences in the atomization characteristics of the test fuels. A total of nine test fluids including six NJFCP fuels and three calibration fluids were used. The experimental data were then used to validate semi-empirical models, developed through years of experience by engine original equipment manufacturers, and modified under the NJFCP, for predicting droplet size and distribution. The work offers effective tools for developing advanced fuel injectors, and generating data that can be used to significantly enhance multidimensional combustor simulation capabilities.

Titanium alloys are used instead of steel and nickel-based alloys to lower the weight of turbines whenever it is applicable. Due to the high manufacturing costs of titanium, near-net-shape processes like laser metal deposition (LMD) processes are an approach to improve the production of new turbomachinery components. Additionally, these processes are also suitable for repair. LMD uses wire or powder as additional material. When highly reactive materials like titanium grade 5 (Ti6Al4V) are processed, wire-based laser metal deposition (LMD-W) processes are superior to powder-based processes due to the smaller reactive surface. Nowadays, three main challenges exist when titanium grade 5 (Ti6Al4V) is processed by additive manufacturing (AM): First of all, the high affinity to oxygen combined with the increased brittleness of the material in case of a contamination with already low amounts of oxygen has to be faced. Second, the material is prone to distortion induced by thermal stress during the manufacturing process. Finally, the material has a complex bimodal microstructure, which has to be adjusted properly to generate optimal strength. The following publication will present how these technical challenges are faced. The heat input into the workpiece and thereby the area that has to be covered with shielding gas is minimized. This is done by minimizing the laser spot size as well as adjusting the travel speed. Thereby a local shielding of the process was realized. With this optimized process, it was possible to generate several specimens for metallurgical analysis.

Large eddy simulations (LES) and experiments (planar laser-induced fluorescence of the hydroxyl radical (OH-PLIF) and pressure transducer) have been carried out on a gas turbine burner fitted to an atmospheric combustion rig. This burner, from the Siemens SGT-800 gas turbine, is a low NO x , partially premixed burner, where preheat air temperature, flame temperature, and pressure drop across the burner are kept similar to engine full load conditions. The large eddy simulations are based on a flamelet-generated manifold (FGM) approach for representing the chemistry and the Smagorinsky model for subgrid turbulence. The experimental data and simulation data are in good agreement, both in terms of time averaged and time-resolved quantities. From the experiments and LES, three bands of frequencies of pressure fluctuations with high power spectral density are found in the combustion chamber. The first two bands are found to be axial pressure modes, triggered by coherent flow motions from the burner, such as the flame stabilization location and the precessing vortex core (PVC). The third band is found to be a cross flow directional mode interacting with two of the four combustion chamber walls in the square section of the combustion chamber, triggered from general flow motions. This study shows that LES of real gas turbine components is feasible and that the results give important insight into the flow, flame, and acoustic interactions in a specific combustion system.

Recent technological advances in the field of additive manufacturing have made possible to manufacture turbine engine components characterized by controlled permeability in desired areas. These have shown great potential in cooling application such as convective cooling and transpiration cooling and may in the future contribute to an increase of the turbine inlet temperature. This study investigates the effects of the pressure ratio, the thickness of the porous material, and the hatch distance used during manufacturing on the discharge coefficient. Moreover, two different porous structures were tested, and in total, 70 test objects were investigated. Using a scanning electron microscope, it is shown that the porosity and pore radius distribution, which are a result from the used laser power, laser speed, and hatch distance during manufacturing, will characterize the pressure losses in the porous sample. Furthermore, the discharge coefficient increases with increasing pressure ratio, while it decreases with increasing thickness to diameter ratio. The obtained experimental data were used to develop a correlation for the discharge coefficient as a function of the geometrical properties and the pressure ratio.

Temperature and composition spots in a turbulent flow are detected and time-resolved using laser-induced thermal grating spectroscopy (LITGS). A 355 nm wavelength particle image velocimetry laser is operated at 0.5–1 kHz to generate the thermal grating using biacetyl as an absorber in trace amounts. In an open laminar jet, a feasibility study shows that small (≃ 3%) fluctuations in the mean flow properties are well captured with LITGS. However, corrections of the mean flow properties by the presence of the trace biacetyl are necessary to properly capture the fluctuations. The actual density and temperature variation in the flow are determined using a calibration procedure validated using a laminar jet flow. Finally, traveling entropy and composition spots are directly measured at different locations along a quartz tube, obtaining good agreement with expected values. This study demonstrates that LITGS can be used as a technique to obtain instantaneous, unsteady temperature and density variations in a combustion chamber, requiring only limited optical access.

This work is motivated by the thermoacoustic instability challenges associated with ultra-low emissions gas turbine (GT) combustors. It demonstrates the first use of high-speed dual-plane orthogonally-polarized stereoscopic-particle image velocimetry (PIV) and synchronized OH planar laser-induced fluorescence in a premixed swirling flame. We use this technique to explore the effects of combustion and longitudinal acoustic forcing on the time- and phase-averaged flow field—particularly focusing on the behavior of the Reynolds stress in the presence of harmonic forcing. We observe significant differences between ensemble-averaged and time-averaged Reynolds stress. This implies that the large-scale motions are nonergodic, due to coherent oscillations in Reynolds stress associated with the convection of periodic vortical structures. This result has important implications on hydrodynamic stability models and reduced-order computational fluid dynamics simulations, which do show the importance of turbulent transport on the problem, but do not capture these coherent oscillations in their models.

Measurement of film thickness between piston ring and cylinder bore has been a challenge for decades; laser-induced fluorescence (LIF) method was used by several groups, and promising results are obtained for the investigation of lubricant film transport. In this study, blue light generated by a laser source is transmitted to a beam splitter by means of a fiber optic cable and combined with another fiber optic line, then transmitted to the piston ring and cylinder bore conjunction. The light causes the fluorescence dye present in the lubricant to emit light in a longer wavelength, i.e., green. Reflected light is recollected; blue wavelength components are filtered out using a narrow band pass optical filter, and only components in the florescence wavelength is transmitted to a photomultiplier tube. The photomultiplier produces a voltage proportional to instantaneous lubricant film thickness. Then, the photomultiplier signal is calibrated for lubricant film thickness using a laser textured cylinder bore with known geometries. Additional marks were etched on the liner for calibration. The LIF system is adapted to a piston ring and cylinder bore friction test system simulating engine conditions. Static piston ring and reciprocating liner configuration of the bench test system allow the collection of continuous lubricant film thickness data as a function of crank angle position. The developed system has potential to evaluate new designs, materials, and surface properties in a controlled and repeatable environment.