In this paper, we investigated the effects of herringbone riblets, a type of bio-inspired micro-scale surface patterns, on the pressure losses and flow turning angles in a linear cascade over a range of low Reynolds numbers from 0.50×10 5 to 1.50×10 5 and at three different angles of attack. Our experiments showed that despite the micro-scale size of herringbone riblets they produced a significant reduction in pressure loss coefficient and a substantial increase in flow turning angle except at the low end of Reynolds numbers tested. In comparison to the baseline case without riblets, the highest reduction in mean pressure loss achieved was 36.4% which was accompanied by an increase of average turning angle of 4.1°. It was observed that the loss reduction is associated with a reduction in the maximum pressure loss at lower angles of attack and a narrower wake zone at higher angles of attack as a result of suppression of flow separation on the blade suction surface. It was also noted that such a significant improvement in performance was accompanied by the appearance of a serrated wake structure in the contours of pressure loss coefficient. The improvement in blade performance was attributed to the secondary flow motion produced by herringbone riblets which energises the boundary layer. Overall, this work has produced convincing experimental evidence that herringbone riblets can be used as passive flow control devices for reducing flow separation in compressors at low Reynolds numbers.

A nonlinear full-wheel time-domain simulation of a two-stage low pressure turbine is presented, analyzed, and compared with the available experimental data. Recent improvements to the computational fluid dynamics (CFD) solver TRACE that lead to significantly reduced wall-clock times for such large scale simulations are described in brief. Since the configuration is characterized by significant unsteady turbulence and transition effects, it is well suited for the validation and benchmarking of frequency-domain methods. Transition, flow separation and wall pressure fluctuations on the stator blades of the second stage are analyzed in detail. A strong azimuthal π -periodicity is observed, manifesting in a significantly varying stability of the midspan trailing edge flow with a quasi-steady closed separation bubble on certain blades and highly dynamic partially open separation bubbles with recurring transition and turbulent reattachment on other blades. The energy spectrum of fluctuating wall quantities in that regime shows a high bandwidth and considerable disharmonic content, which is challenging for frequency-domain-based simulation methods.

The results of this investigation come from two linear cascades at high diffusion factors (DFs). The measurements presented for each low-pressure turbine (LPT) profile were conducted at midspan under a range of Reynolds- and exit Mach numbers. The exit Mach number was varied in a range covering low subsonic up to values where a transonic flow regime on the suction side of the blade could be expected. This work focuses on two profiles with a diffusion factor in a range of 0.18 ≤ DF ≤ 0.22 , where values in this range are considered as a comparable for the two cascades. Profile A is a front-loaded design and has shown no obvious flow separation on the suction side of the blade. Compared to the design A, design B is a more aft-loaded profile which exhibits flow separation on the suction side for all Reynolds numbers investigated. The integral total pressure losses were evaluated by wake traverses downstream of the airfoil. To determine the isentropic Mach numbers and the character of the boundary layer along the suction side of the profile, the static pressure measurements and traverses with a flattened Pitot probe were carried out. A correlation between the position of maximum Mach number on the suction side and the integral total pressure losses has been successfully established. The results show that the optimum location of peak Mach number to minimize integral total pressure losses is significantly dependent on the Reynolds number. However, the correlation presented in this paper, which is based on the data of the integral total pressure losses of an attached boundary layer, is not able to predict the integral total pressure loss or the location of the maximum Mach number on the suction side of the blade when an open separation bubble occurs.

This paper discusses the impact of a nonsteady outflow condition on the compressor stator flow that is forced through a mimic in the wake of a linear low-speed cascade to simulate the conditions that would be expected in a pulsed detonation engine. 2D/3C-PIV measurements were made to describe the flow field in the passage. Detailed wake measurements provide information about static pressure rise as well as total pressure loss. The stator profile used for the investigations is highly loaded and operates with three-dimensional flow separations under design conditions and without active flow control. It is shown that sidewall actuation helps stabilize the flow field at every phase angle and extends the operating range of the compressor stator. Furthermore, the static pressure gain can be increased by 6% with a 4% loss reduction in time-averaged data.

Film cooling experiments were run at the high-speed cascade wind tunnel of the University of the Federal Armed Forces Munich. The investigations were carried out on a linear cascade of highly loaded turbine blades. The main targets of the tests were to assess the film cooling effectiveness and the heat transfer in zones with main flow separation. The previous cascade was designed to have a large zone with flow separation on the pressure side starting at the leading edge and reaching up to approximately half of the axial chord. This cascade was changed for a new design with a larger pitch to chord ratio in order to set the focus on flow separation on the suction side. This increased pitch forces a massive separation on the suction side due to strong shocks. The flow separation is controlled with aid of vortex generating jets in order to reduce the total pressure loss caused by it. Film cooling is provided on the suction side upstream of the vortex generating jets. The measurements comprise of blade loading, profile loss, adiabatic film cooling effectiveness, and heat transfer coefficient under two Mach numbers at a Reynolds number of 390,000. In a previous publication detailed results with homogeneous inflow where shown. Now, the focus is set on the effects of periodic unsteady wakes resulting from bars moving upstream of the cascade. These moving bars create a periodic unsteady inflow similar to the interaction between stator and rotor in the machine. It is shown how these wakes have significant influence on the heat transfer in the acceleration region of the suction side and affect the adiabatic film cooling effectiveness upstream of the shock.

Film cooling experiments were run at the high speed cascade wind tunnel of the University of the Federal Armed Forces Munich. The investigations were carried out with a linear cascade of highly loaded turbine blades. The main targets of the tests were to assess the film cooling effectiveness and the heat transfer in zones with main flow separation. Therefore the blades were designed to force the flow to detach on the pressure side shortly downstream of the leading edge and it reattaches at about half of the axial chord. In this zone, film cooling rows are placed among others for reduction of the size of the separation bubble. The analyzed region on the blade is critical due to the high heat transfer present at the leading edge and at the reattachment line after main flow separation. Film cooling can contribute to a reduction of the size of the separation bubble reducing aerodynamic losses but increases in general heat transfer due to turbulent mixing. The reduction of the size of the separation bubble might also be two-fold since it acts like a thermal insulator on the blade and reducing the size of the bubble might lead to stronger heating of the blade. Film cooling should therefore take into account both: firstly, a proper protection of the surface, and secondly, reduce aerodynamic losses diminishing the extension of the main flow separation. The overall effectiveness of film cooling for a real engine has to combine heat transfer with film cooling effect. In this paper, the overall effectiveness of film cooling, combining results from measurements of the adiabatic film cooling effectiveness and the local heat transfer coefficient are shown. The tests comprise the analysis of the effect of different outlet Mach and Reynolds numbers at engine relevant values and film cooling ratio. A new parameter is introduced which allows for the evaluation of the effect of film cooling accounting at the same time for the change of local heat transfer coefficient. To the authors’ opinion this parameter allows a better, physically based assessment than the strategy using the so-called heat flux ratio. A parameter study is carried out in order to benchmark the effect of changes of the blade design.

Film cooling experiments were run at the high speed cascade wind tunnel of the University of the Federal Armed Forces Munich. The investigations were carried out with a linear cascade of highly loaded turbine blades. The main objectives of the tests were to assess the film cooling effectiveness and the heat transfer in zones with main flow separation. Therefore, the blades were designed to force the flow to detach on the pressure side shortly downstream of the leading edge and reattach at about half of the axial chord. In this zone, film cooling rows are placed among others for a reduction of the size of the separation bubble. The analyzed region on the blade is critical due to the high heat transfer present at the leading edge and at the reattachment line after the main flow separation. Film cooling can contribute to a reduction of the size of the separation bubble reducing aerodynamic losses, however, in general, it increases heat transfer due to turbulent mixing. The reduction of the size of the separation bubble might also be twofold, since it acts like a thermal insulator on the blade and reducing the size of the bubble might lead to a stronger heating of the blade. Film cooling should, therefore, take both into account: first, a proper protection of the surface and second, reducing aerodynamic losses, diminishing the extension of the main flow separation. While experimental results of the adiabatic film cooling effectiveness were shown in previous publications, the local heat transfer is analyzed in this paper. Emphasis is also placed upon analyzing, in detail, the flow separation process. Furthermore, the tests comprise the analysis of the effect of different outlet Mach and Reynolds numbers and film cooling. In part two of this paper, the overall film cooling effectiveness is addressed. Local heat transfer is still difficult to predict with modern numerical tools and this is especially true for complex flows with flow separation. Some numerical results with the Reynolds averaged Navier-Stokes (RANS) and large eddy simulation (LES) show the capability of a commercial solver in predicting the heat transfer.

In centrifugal compressors, variable inlet guide vanes (IGVs) are used to control the mass flow rate with negligible change in pressure ratio and shaft speed. The efficient operation of IGVs is limited to the range of aerodynamic stability of their vane profiles. Thin symmetric profiles, which are usually used, tend to exhibit flow separation already at low setting angles, resulting in a rapid decrease in the global efficiency. Three different guide vane profiles, including a symmetric reference profile, a two-piece tandem profile with a variable angle, and an s-cambered profile, together with two auxiliary profiles, were considered. These variants were numerically and experimentally investigated at different setting angles, covering negative and positive inlet swirls, and at different operating points. The results show that tandem and s-cambered vanes have superior aerodynamic performance in comparison with the symmetric reference profile and extend the operating range of the compressor over which the efficiency remains high. The tandem profile shows better aerodynamic performance than the s-cambered profile at negative inlet swirl, while the asymmetric s-cambered profile offers an extended range of high efficiency at positive preswirl. Considering manufacturing requirements and cost, the s-cambered profile is preferred for applications with positive preswirl.

AITEB-2 is a project where aerothermal challenges of modern high pressure turbine designs are analyzed. One of the scopes of the project is to allow for new gas turbine designs with less parts and lighter jet engines by increasing the blade pitch and therefore the aerodynamic blade loading. For transonic profiles, this leads to very high velocities on the suction side and shock induced separation is likely to occur. The total pressure loss increase due to flow separation and strong shocks, as well as the underturning of the flow, limits the increase of the blade pitch. In this paper, experiments using a linear turbine blade cascade with high aerodynamic loading are presented. The blade pitch is increased such that at design conditions, a strong separation occurs on the suction side. The experiments were run at high subsonic exit Mach numbers and at Reynolds numbers of 390,000 and 800,000. In order to reduce the flow separation and the aerodynamic losses, air jet vortex generators are used, which create streamwise vortices prior to the separation start. Since in high pressure turbine blades film cooling is widely used, also the influence of film cooling both with and without using vortex generators is analyzed. Film cooling is provided on the suction side by two rows of cylindrical holes. This paper provides an analysis of the influence of different main flow conditions, film cooling, and vortex generators on total pressure loss, heat transfer and film cooling effectiveness. The experiments show that the vortex generators, as well as the film cooling reduce flow separation and total pressure losses. The effects are also seen in the local heat transfer, especially with enhanced heat transport in the region with flow separation. The cases presented in this paper deal with complex flow phenomena, which are challenging to be predicted with modern numerical tools correctly. Therefore, the experimental data serve as a comprehensive database for validation of simulation tools in the AITEB-2 project.

Flow separation control was investigated on a compressor cascade using three types of fluidic-based excitations: steady suction, steady blowing, and synthetic jet. By solving unsteady Reynolds–averaged Navier–Stokes equations, the effect of excitation parameters (amplitude, angle, and location) on performance was addressed. The results show that the separated flow can be controlled by the fluidic-based actuators effectively and the time-averaged performance of the flow field can be improved remarkably. Generally, the improvement can be enhanced when the amplitude of excitation is increased. The optimal direction varies with each type of excitations and is related to physical mechanisms underlying the separation control. For two types of steady excitations, the most effective jet location is at a distance upstream of the time-averaged separation point and the synthetic jet is just at the separation point.

Film cooling experiments were performed using a highly loaded high pressure turbine blade blade linear cascade. A large region with main flow separation is found on the pressure side and film cooling is provided into this area with three rows of either cylindrical or fan-shaped holes. The measurements comprise adiabatic film cooling effectiveness and profile static pressure measurements. The surface temperature was acquired with thermochromatic liquid crystals and using a hue to temperature correlation. The results shown are for variations in main flow Mach and Reynolds numbers at engine relevant levels and of coolant mass flows. The results for steady and periodic unsteady inflows with highly turbulent wakes created by cylindrical bars moving upstream in a plane parallel to the cascade are compared as two-dimensional surface plots, laterally averaged film cooling effectiveness and overall effectiveness over the entire surface.

This paper presents a numerical study of the turbulent flows through a number of 2D and 3D 180 deg U -ducts, with and without guide vanes, using the Reynolds-averaged Navier–Stokes method. Computations have been first carried out for a 2D U -duct flow ( W / H = 1.0 ) with four turbulence models (V2F, k - ε , shear stress transport (SST), and Reynolds stress). The models’ capability for predicting streamline curvature effects on turbulence and separation has been assessed, using flow and turbulence data. The effects of adding a guide vane inside the bend have been analyzed to reduce/avoid flow separation. Three vanes with different radial locations have been studied, and the mechanism for pressure loss reduction has been examined. Analyses have been performed for turbulent flows in 3D U -ducts with square cross section and sharp 180 deg turning ( W / D = 0.2 ) , similar to the U -bends in typical turbine blade cooling passages. The predictions are compared with the data of outer-wall pressure. The effects of the guide vane and outer-wall shape on the flow separation, secondary-flow vortices, and pressure loss have been evaluated. The combined vane and uniform cross section area are found to improve the flow distribution and reduce the pressure loss significantly.

Comprehensive experimental investigations were conducted to get deeper insight into the physics of stator clocking in turbomachines. Different measurement techniques were used to investigate the influence of varying clocking positions on the highly unsteady flow field in a 1.5-stage axial low-pressure (LP) turbine. A Reynolds number typical for LP turbines as well as a two-dimensional blade design were chosen. Stator 2 was developed as a high-lift profile with a separation bubble on the suction side. This paper presents the results that were obtained by means of static pressure tappings and five-hole probes as well as the time-averaged results of unsteady x-wire measurements. The probes were traversed in different measuring planes for ten clocking positions. Depending on the clocking position, a variation in total pressure loss for Stator 2, a change of the rotor exit flow angle, and a dependency of the Stator 2 exit flow angle were found. The influence of these parameters on turbine efficiency was studied. Three main factors affecting the total pressure loss could be separated: the size of the separation bubble, the production of turbulent kinetic energy, and the strength of the periodic fluctuations downstream of Stator 2.

Comprehensive experimental investigations were conducted to get deeper insight into the physics of stator clocking in turbomachines. Different measurement techniques were used to investigate the influence of varying clocking positions on the highly unsteady flow field in a 1.5-stage axial low-pressure (LP) turbine. A Reynolds number typical for LP turbines as well as a two-dimensional blade design were chosen. Stator 2 was developed as a high-lift profile with a separation bubble on the suction side. This paper presents the results that were obtained by means of unsteady x-wire measurements upstream and downstream of Stator 2 and surface mounted hot-film measurements on the Stator 2 suction side. It was found that for the case when the Stator 1 wakes impinge close to the leading edge of Stator 2 the interaction between the Stator 1 and the rotor vortical structures takes place in proximity of the Stator 2 boundary layer, which leads to a shift of the transition point in the upstream direction. The major loss parameter concerning the Stator 2 aerodynamic performance could be attributed to the strength of the periodic fluctuations within the Stator 2 suction side boundary layer. A phase shift in the quasiwall shear stress signal in the front region of the Stator 2 vane was observed for different clocking positions.

This paper presents an experimental study of the behavior of leakage flow across shrouded turbine blades. Stereoscopic particle image velocimetry and fast response aerodynamic probe measurements have been conducted in a low-speed two-stage axial turbine with a partial shroud. The dominant flow feature within the exit cavity is the radially outward motion of the main flow into the shroud cavity. The radial migration of the main flow is induced by flow separation at the trailing edge of the shroud due to a sudden area expansion. The radially outward motion is the strongest at midpitch as a result of interactions between vortices formed within the cavity. The main flow entering the exit cavity divides into two streams. One stream moves upstream toward the adjacent seal knife and reenters the main flow stream. The other stream moves downstream due to the interaction with the thin seal leakage flow layer. Closer to the casing wall, the flow interacts with the underturned seal leakage flow and gains swirl. Eventually, axial vorticity is generated due to these complex flow interactions. This vorticity is generated by a vortex tilting mechanism and gives rise to additional secondary flow. Because of these fluid motions combined with a contoured casing wall, three layers (the seal leakage layer, cavity flow layer, and main flow) are formed downstream of the shroud cavity. This result is different from the two-layer structure, which is found downstream of conventional shroud cavities. The seal leakage jet formed through the seal clearance still exists at 25.6% axial chord downstream of the second rotor. This delay of complete dissipation of the seal leakage jet and its mixing with the cavity flow layer is due to the contoured casing wall. Time-averaged flow downstream of the shroud cavity shows the upstream stator’s influence on the cavity flow. The time-averaged main flow can be viewed as a wake flow induced by the upstream stator whose separation at the shroud trailing edge induces pitchwise non-uniformity of the cavity flow.

Measurements were taken of the vortex system and turbulent flow that resulted from the interaction between a stator blade and the approaching endwall boundary layer in a linear cascade of compressor blades. Data were taken at a Reynolds number based on blade chord of 640,000. Five-hole pressure measurements were conducted upstream and downstream of the blade row. The approaching boundary layer was also characterized with the laser-Doppler velocimeter. Downstream three-component laser-Doppler velocimetry surveys were conducted at three streamwise stations to map the location and velocity characteristics of the wake and vortex system. Results clearly showed the extent of the vortex emanating from the separation of the boundary layer on the suction side of the blade. Finally, all components of mean flow velocity and turbulence are documented for the last survey station. These data will form a challenging test case for numerical code validation.

Modern design of turbine blades usually requires highly loaded, very thin profiles in order to save weight and cost. If local leading edge incidence is kept close to zero, then flow separation might occur on the pressure side. Although it is known that flow separation, flow reattachment, and the associated zones of recirculation have a major impact on the heat transfer to the wall, the turbomachinery community needs an understanding of the heat transfer mechanisms in separated flows as well as models and correlations to predict them. The aim of the present investigation is a detailed study by means of an in-house CFD code, MU 2 S 2 T , of the heat transfer mechanisms in separated flows, in particular in separation and reattachment point regions. Furthermore, an attempt is made to identify a limited number of parameters (i.e., Re, M, inlet flow angle, etc.) whose influence on the heat flux would be critical. The identification of these parameters would be the starting point to develop special correlations to estimate the heat transfer in separated flow regions.

Many GE frame gas turbines have a unique 90-deg tailpipe exhaust system that contains struts, diffusers, and turning vanes. As confirmed in a recent report by GE and other authors, it is known in the industry that this tailpipe design has large pressure losses. In this recent report a pressure loss as high as 60 in. of water (0.15 kgs/sqcm) was cited. Due to the flow separations they create, the report indicates that the struts can cause very high-pressure losses in the turbine. The report also states that these pressure losses can vary with different turbine load conditions. Cheng Fluid Systems and Cheng Power Systems have conducted a study aimed at substantially reducing these pressure losses. Flow control technology introduced to the refinery industry, i.e., the Cheng Rotation Vane (CRV) and the Large Angle Diffuser (LAD) can be used to mitigate the flow separation and turbulence that occurs in turns, bends, and large sudden expansions. Specifically the CRV addresses the flow separations in pipe turns, and the LAD addresses the flow problems that occur with large sudden expansion areas. The paper will introduce the past experience of the CRV and LAD, and will then use computer simulations to show the flow characteristics around a new design. First, the study meticulously goes through the entire GE exhaust system, starting with the redesign of the airfoil shape surrounding the struts. This new design has a larger angle of attack and minimizes the flow separations over a much wider operating range. Second, the pros and cons of the concentric turning vanes are studied and it is shown that they are more flow restrictive, rather than flow enhancing. Third, it is shown that the highly turbulent rectangular box-type exhaust ducting design, substantially contributes to high noise levels and pressure losses. In this paper a completed design will be shown that incorporates a new airfoil shape for the struts, and by using CRV flow technology in combination with the LAD flow technology, the pressure recovery can be enhanced. If the pressure losses could be reduced by 40 inches of water (0.10 kgs/sqcm), the turbine efficiency could be increased by 5%, and the power output could be increased by 6%.

This paper documents an investigation conducted on the aerodynamic response of a turbine blade oscillating in a three-dimensional bending mode under massive tip separation. Flow separation near the tip of the blade was realized by use of a step placed upstream of the blade’s leading edge. Extensive blade surface steady and unsteady pressure measurements were obtained from a test facility with clearly defined boundary conditions for a range of reduced frequency. The experiment is designed to produce detailed and reliable 3D test cases for aeroelastic applications. A complete set of steady and unsteady blade surface pressure measurements is provided for five spanwise sections at 10, 30, 50, 70, and 90 percent of span. In addition, the issue of linearity is addressed. Experimental results demonstrate a predominant linear behavior of the unsteady pressure response.

A mathematical model is developed to analyze the unsteady flow through an harmonically oscillating cascade of airfoils, including separated flow. The model incorporates an inverse integral boundary layer solution with the time-marching Euler analysis NPHASE. An embedded composite grid formulation is incorporated, specifically a deforming C-grid embedded in a Cartesian H-grid, thereby simplifying grid generation. To reduce computational requirements, Fourier series unsteady periodic boundary conditions are implemented. The integral turbulent boundary layer model is closed with steady correlations adopted in a quasi-steady manner. To couple the inviscid and viscous solutions, the viscous effect is modeled in the unsteady Euler solution in a quasi-steady manner by a transpiration boundary condition. An isolated airfoil is used to compare the steady interaction model with experimental data. Then a flat plate cascade is used to verify the unsteady flow solver with linear theory predictions. An experimental unsteady aerodynamics data set of a loaded cascade with separated meanflow executing torsional oscillations compared favorably with the analysis. The code is then utilized to study the effect of flow separation on the unsteady aerodynamics.