Effects of tip clearance size and flowrate on the flow around the tip of an axial turbomachine rotor are studied experimentally. Visualizations and stereo-particle image velocimetry (PIV) measurements in a refractive index-matched facility compare the performance, leakage velocity, and the trajectory, growth rate, and strength of the tip leakage vortex (TLV) for gaps of 0.49% and 2.3% of the blade chord, and two flowrates. Enlarging the tip clearance delays the TLV breakup in the aft part of the rotor passage at high flowrates but causes earlier breakup under pre-stall conditions. It also reduces the entrainment of endwall boundary layer vorticity from the separation point where the leakage and passage flows meet. Reducing the flowrate or tip gap shifts the location of the TLV detachment from the blade suction side (SS) upstream to points where the leakage velocity is 70–80% of the tip speed. Once detached, the growth rates of the total shed circulation are similar for all cases, i.e., varying the gap or flowrate mostly shifts the detachment point. The TLV migration away from the SS decreases with an increasing gap but not with the flowrate. Two mechanisms dominate this migration: initially, the leakage jet pushes the TLV away from the blade at 50% of the leakage velocity. Further downstream, the TLV is driven by its image on the other side of the endwall. Differences in migration rate are caused by the smaller distance between the TLV and its image for the narrow gap, and the increase in initial TLV strength with decreasing flowrate and gap.

When a multistage high-speed compressor is operated away from its design point, extreme incidence is caused in some blade rows. This results in large, localized separations that are three dimensional in nature. In this paper, topological reasoning is used to describe the behavior of these three-dimensional separations. It is shown that two classes of separation exist: one in which the flow progresses from attached to separate in a smooth way and another where there is a discontinuity in the response of the flow topology. It is shown that the global structure of the flow depends on the type of topological response that occurs. When the response is discontinuous, nonaxisymmetric cells of separated blades are formed. When the response is smooth, the resultant separated flow is axisymmetric. The paper is split into two broad sections: The first section presents examples of the two different classes of topological response that can occur in a single blade row, and it also shows how an engineer can achieve a different response by altering the blade design. The second section covers the analysis of a multistage high-speed compressor. The compressor initially presents the discontinuous behavior with rotating cells of separations. It is then redesigned to reduce the severity of the cell behavior or remove it entirely.

The aerodynamic interaction of upstream and downstream blade rows can have a significant impact on the forced response of the compressor. Previously, the authors carried out the forced response analysis of a three-row stator-rotor-stator (S1-R2-S2) configuration from a 3.5-stage compressor. However, since the stator vane counts in both the stators (S1 and S2) were the same, it was not possible to separate the excitations from both the rows as they excited the rotor at the same frequency. Hence, a new configuration was developed and tested in which the stator 1 blade count was changed to 38 and stator 2 blade count was maintained at 44 in order to study the individual influences of the stator on the embedded rotor. By using this method, the excitations from both rows can be determined, and the excitations can be quantified to determine the row having the maximum influence on the overall forcing. To achieve this, two sets of simulations were carried out. The three-row stator-rotor (S1-R2-S2) simulation was carried out at both the 38EO (engine order) and 44EO crossings at the peak efficiency (PE) operating condition. The two-row stator-rotor analysis (S1-R2) was carried out at the 38EO crossing, and the other two-Row (R2-S2) analyses were carried out at the 44EO crossing. The steady aerodynamics was preserved in both the cases. A study was done to determine the contribution of wave reflections from the stator inlet and exit planes to the forcing function. Two conclusions drawn from this study are as follows: (1) the modal force value decreased after the upstream stator was removed, which proved that wave reflections from this stator were significant and (2) the increase in modal force was in-line with experimental observations.

In this paper, we investigate the coupled interaction between a new short intake design with a modern fan in a high-bypass ratio civil engine, specifically under the off-design condition of high incidence. The interaction is expected to be much more significant than that on a conventional intake. The performance of both the intake-alone and rotor-alone configurations are examined under isolation. Subsequently, a comprehensive understanding on the two-way interaction between intake and fan is presented. This includes the effect of fan on intake angles of attack (AoA) tolerance (FoI) and the effect of circumferential and radial flow distortion induced by the intake on the fan performance (IoF). In the FoI scenario, the rotor effectively redistributes the mass flow at the fan-face. The AoA tolerance of the short-intake design has increased by ≈4 deg when compared with the intake-alone configuration. Dynamic nature of distortion due to shock unsteadiness has been quantified. ST plots and power spectral density (PSD) of pressure fluctuations show the existence of a spectral gap between the shock unsteadiness and blade passing, with almost an order of magnitude difference in the corresponding frequencies. In the IoF scenario, both the “large” (O(360 deg)) and “small” scale distortion (O(10–60 deg)) induced by the intake results in a non-uniform inflow to the rotor. Sector analysis reveals a substantial variation in the local operating condition of the fan as opposed to its steady characteristic. Streamline curvature, upwash, and wake thickening are identified to be the three key factors affecting the fan performance. These underlying mechanisms are discussed in detail to provide further insights into the physical understanding of the fan-intake interaction. In addition to the shock-induced separation on the intake lip, the current study shows that shorter intakes are much more prone to the upwash effect at higher AoA. Insufficient flow straightening along the engine axis is reconfirmed to be one of the limiting factors for the short-intake design.

The flow through a transonic compressor cascade shows a very complex structure due to the occurring shock waves. In addition, the interaction of these shock waves with the blade boundary layer inherently leads to a very unsteady flow behavior. The aim of the current investigation is to quantify this behavior and its influence on the cascade performance as well as to describe the occurring transonic flow phenomena in detail. Therefore, an extensive experimental investigation of the flow in a transonic compressor cascade has been conducted within the transonic cascade wind tunnel of DLR Institute of Propulsion Technology at Cologne. In this process, the flow phenomena were thoroughly examined for an inflow Mach number of 1.21. The experiments investigate both the laminar and the turbulent shock wave boundary layer interaction within the blade passage and the resulting unsteady behavior. The experiments show a fluctuation range of the passage shock wave of about 10% chord for both cases, which is directly linked with a change of the inflow angle and of the operating point of the cascade. Thereafter, Reynolds-averaged Navier–Stokes (RANS) simulations have been performed aiming at the verification of the reproducibility of the experimentally examined flow behavior. Here, it is observed that the dominant flow effects are not reproduced by a steady numerical simulation. Therefore, a further unsteady simulation has been carried out to capture the unsteady flow behavior. The results from this simulation show that the fluctuation of the passage shock wave can be reproduced but not in the correct magnitude. This leads to a remaining weak point within the design process of transonic compressor blades because the working range will be overpredicted. The resulting conclusion of this study is that the use of scale-resolving methods such as LES or the application of DNS is necessary to correctly predict unsteadiness of the transonic cascade flow and its impact on the cascade performance.

The optimum aspect ratio at which maximum efficiency occurs is relatively low, typically between 1 and 1.5. At these aspect ratios, inaccuracies inherently exist in the decomposition of the flow field into freestream and endwall components due to the absence of a discernible freestream. In this paper, a unique approach is taken: a “linear repeating stage” concept is used in conjunction with a novel way of defining the freestream flow. Through this approach, physically accurate decomposition of the flow field for aspect ratios as low as ∼0.5 can be achieved. This ability to accurately decompose the flow leads to several key findings. First, the endwall flow is found to be dependent on static pressure rise coefficient and endwall geometry, but independent of the aspect ratio. Second, the commonly accepted relationship that endwall loss coefficient varies inversely with the aspect ratio is shown to be physically inaccurate. Instead, a new term, which the authors refer to as the “effective aspect ratio,” should replace the term “aspect ratio.” Moreover, not doing so can result in efficiency errors of ∼0.6% at low aspect ratios. Finally, there exists a low aspect ratio limit below which the two endwall flows interact causing a large separation to occur along the span. From these findings, a low-order model is developed to model the effect of varying aspect ratio on compressor performance. The last section of the paper uses this low-order model and a simple analytical model to show that to a first order, the optimum aspect ratio is just a function of the loss generated by the endwalls at zero clearance and the rate of change in profile loss due to blade thickness. This means that once the endwall configuration has been selected, i.e., cantilever or shroud, the blade thickness sets the optimum aspect ratio.

Secondary flow limits the aerodynamic loading level of turbomachinery. Vortex generators (VGs) offer the potential to attenuate secondary flow when implemented at the endwall of the blade passage. Customary design usually relies on computational fluid dynamics (CFD); however, VG geometry modeling and mesh generation are challenging. This paper presents an efficient method for designing the optimal VG layout. In this approach, first, a mathematical model (BAYC) is introduced to replace the actual VGs; hence, simulation can be carried out without detailed VG gridding. Second, an optimization procedure with response surface methods is employed to determine the optimal VG layout. To illustrate the proposed method, compressor cascades with one and three VGs are used as the test cases. The results demonstrate that the optimal VG layout may effectively weaken the secondary flow and can decrease the aerodynamic loss by 15–25% in almost all incidence angle ranges, particularly at positive incidence angles. Flow mechanism analysis indicates that VGs can enhance the boundary layer kinetic energy, thereby elevating the capability to withstand adverse pressure gradients.

Shock control bumps can help to delay and weaken shocks, reducing loss generation and shock-induced separation and delaying stall inception for transonic turbomachinery components. The use of shock control bumps on turbomachinery blades is investigated here for the first time using 3D analysis. The aerodynamic optimization of a modern research fan blade and a highly loaded compressor blade is carried out using shock control bumps to improve their performance. Both the efficiency and stall margin of transonic fan and compressor blades may be increased through the addition of shock control bumps to the geometry. It is shown how shock-induced separation can be delayed and reduced for both cases. A significant efficiency improvement is shown for the compressor blade across its characteristic, and the stall margin of the fan blade is increased by designing bumps that reduce shock-induced separation near to stall. Adjoint surface sensitivities are used to highlight the critical regions of the blade geometries, and it is shown how adding bumps in these regions improves blade performance. Finally, the performance of the optimized geometries at conditions away from where they are designed is analyzed in detail.

The measurement accuracy of the temperature/pressure probe mounted at the leading edge of a turbine/compressor blade is crucial for estimating the fuel consumption of a turbo-fan engine. Apart from the measurement error itself, the probe also introduces extra losses. This again would compromise the measurement accuracy of the overall engine efficiency. This paper utilizes high-fidelity numerical analysis to understand the complex flow around the probe and quantify the loss sources due to the interaction between the blade and its instrumentation. With the inclusion of leading-edge probes, three-dimensional flow phenomena develop, with some flow features acting in a similar manner to a jet in cross flow. The separated flow formed at the leading edge of the probe blocks a large area of the probe bleedhole, which is one of the reasons why the probe accuracy can be sensitive to Mach and Reynolds numbers. The addition of 4% free-stream turbulence is shown to have a marginal impact on the jet trajectory originated from the probe bleedhole. However, a slight reduction is observed in the size of the separation bubble formed at the leading edge of the probe, preceding the two bleedhole exits. The free-stream turbulence also has a significant impact on the size of the separation bubble near the trailing edge of the blade. With the addition of the free-stream turbulence, the loss observed within the trailing edge wake is reduced. More than 50% of the losses at the cascade exit are generated by the leading-edge probe. A breakdown of the dissipation terms from the mean flow kinetic energy equation demonstrates that the Reynolds stresses are the key terms in dissipating the counter-rotating vortex pairs with the viscous stresses responsible for the boundary layer.

Truncating the exit of a discrete passage centrifugal compressor diffuser is observed to enhance a research compressor's stall line. By interrogating the experimental data along with a set of well-designed Reynolds-Averaged Navier–Stokes computations, this improvement is traced to the reduced impact of secondary flows on the truncated diffuser's boundary layer growth. The secondary flow system is characterized by counter-rotating streamwise vortex pairs that persist throughout the diffuser passage. The vortices originate from two sources: flow nonuniformity at the impeller exit and separation off the leading edge cusps unique to a discrete passage diffuser. The latter detrimentally impacts the diffuser pressure rise capability by accumulating high loss flow along the diffuser wall near the plane of symmetry between the vortices. This contributes to a large passage separation in the baseline diffuser. Using reduced-order modeling, the impact of the vortices on the boundary layer growth is shown to scale inversely with the diffuser aspect ratio, and thus, the separation extent is reduced for the truncated diffuser. Because the diffuser incidence angle influences the strength and location of the vortices, this mechanism can affect the slope of the compressor's pressure rise characteristic and impact its stall line. Stall onset for the baseline diffuser configuration is initiated when the vortex location and the corresponding passage separation transition from pressure to suction side with increased cusp incidence. Conversely, because the extent of the passage separation in the truncated diffuser is diminished, the switch in separation side does not immediately initiate instability.

This paper describes the role of tip leakage flow in creating the leading edge separation necessary for the onset of spike-type compressor rotating stall. A series of unsteady multipassage simulations, supported by experimental data, are used to define and illustrate the two competing mechanisms that cause the high incidence responsible for this separation: blockage from a casing-suction-surface corner separation and forward spillage of the tip leakage jet. The axial momentum flux in the tip leakage flow determines which mechanism dominates. At zero tip clearance, corner separation blockage dominates. As clearance is increased, the leakage flow reduces blockage, moving the stall flow coefficient to lower flow, i.e., giving a larger unstalled flow range. Increased clearance, however, means increased leakage jet momentum and contribution to leakage jet spillage. There is thus a clearance above which jet spillage dominates in creating incidence, so the stall flow coefficient increases and flow range decreases with clearance. As a consequence, there is a clearance for maximum flow range; for the two rotors in this study, the value was approximately 0.5% chord. The chordwise distribution of the leakage axial momentum is also important in determining stall onset. Shifting the distribution toward the trailing edge increases flow range for a leakage jet dominated geometry and reduces flow range for a corner separation dominated geometry. Guidelines are developed for flow range enhancement through control of tip leakage flow axial momentum magnitude and distribution. An example is given of how this might be achieved.

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.

Large eddy simulation (LES) is used to explore the boundary layer transition mechanisms in two rectilinear compressor cascades. To reduce numerical dissipation, a novel locally adaptive smoothing (LAS) scheme is added to an unstructured finite volume solver. The performance of a number of subgrid scale (SGS) models is explored. With the first cascade, numerical results at two different freestream turbulence intensities (Ti's), 3.25% and 10%, are compared. At both Ti's, time-averaged skin-friction and pressure coefficient distributions agree well with previous direct numerical simulations (DNS). At Ti = 3.25%, separation-induced transition occurs on the suction surface, while it is bypassed on the pressure surface. The pressure surface transition is dominated by modes originating from the convection of Tollmien–Schlichting waves by Klebanoff streaks. However, they do not resemble a classical bypass transition. Instead, they display characteristics of the “overlap” and “inner” transition modes observed in the previous DNS. At Ti = 10%, classical bypass transition occurs, with Klebanoff streaks incepting turbulent spots. With the second cascade, the influence of unsteady wakes on transition is examined. Wake-amplified Klebanoff streaks were found to instigate turbulent spots, which periodically shorten the suction surface separation bubble. The celerity line corresponding to 70% of the free-stream velocity, which is associated with the convection speed of the amplified Klebanoff streaks, was found to be important.

Present paper developed a series of additively manufactured parallel cooling channels with streamwise wall jets inside, which could be suitable for double-wall and near-wall cooling configurations in gas turbine hot section components. The tested coupons consisted of parallel channels, each channel further divided into small chambers using several spanwise separation walls. Height of these walls was kept less than channel height, thus forming a slot with one of the end walls. Coolant entered from one side of channel and formed streamwise wall jet while crossing through the slot over to the downstream chamber. The test coupons were additively manufactured by selective laser sintering (SLS) technique using Inconel 718 alloy. Steady-state heat transfer experiments with constant wall temperature boundary condition were performed to analyze effect of pitch between subsequent slots and blockage ratio (ratio of separation wall height to channel height) on heat transfer. The channel Reynolds number ranged from 1800 to 5000. Numerical simulations were performed using ANSYS cfx solver with SST k–ω turbulence model to obtain detailed understanding of existing flow field. Experimental results showed heat transfer enhancement of up to 6.5 times that of a smooth channel for the highest blockage ratio of 0.75. Numerical results revealed complex flow field which consisted of wall jets along with impingement, separation, and recirculation zones in each chamber. For all configurations, gain in heat transfer was accompanied with high pressure drops. However, coupled with the high heat transfer, this design could lead to potential coolant savings.

Experimental data describing laminar separation bubbles developing under strong adverse pressure gradients, typical of ultra-high-lift turbine blades, have been analyzed to define empirical correlations able to predict the main features of the separated flow transition. Tests have been performed for three different Reynolds numbers and three different free-stream turbulence intensity levels. For each condition, around 4000 particle image velocimetry (PIV) snapshots have been acquired. A wavelet-based intermittency detection technique, able to identify the large scale vortices shed as a consequence of the separation, has been applied to the large amount of data to efficiently compute the intermittency function for the different conditions. The transition onset and end positions, as well as the turbulent spot production rate, are evaluated. Thanks to the recent advancements in the understanding on the role played by Reynolds number and free-stream turbulence intensity on the dynamics leading to transition in separated flows, guest functions are proposed in the paper to fit the data. The proposed functions are able to mimic the effects of Reynolds number and free-stream turbulence intensity level on the receptivity process of the boundary layer in the attached part, on the disturbance exponential growth rate observed in the linear stability region of the separated shear layer, as well as on the nonlinear later stage of completing transition. Once identified the structure of the correlation functions, a fitting process with own and literature data allowed us to calibrate the unknown constants. Results reported in the paper show the ability of the proposed correlations to adequately predict the transition process in the case of separated flows. The correlation for the spot production rate here proposed extends the correlations proposed in literature for attached (by-pass like) transition process, and could be used in γ –Re ϑ codes, where the spot production rate appears as a source term in the intermittency function transport equation.

This work, a continuation of a series of investigations on the aerodynamics of aggressive interturbine ducts (ITD), is aimed at providing detailed understanding of the flow physics and loss mechanisms in four different ITD geometries. A systematic experimental and computational study was carried out by varying duct outlet-to-inlet area ratios (ARs) and mean rise angles while keeping the duct length-to-inlet height ratio, Reynolds number, and inlet swirl constant in all four geometries. The flow structures within the ITDs were found to be dominated by the boundary layer separation and counter-rotating vortices in both the casing and hub regions. The duct mean rise angle determined the severity of adverse pressure gradient in the casing's first bend, whereas the duct AR mainly governed the second bend's static pressure rise. The combination of upstream wake flow and the first bend's adverse pressure gradient caused the boundary layer to separate and intensify the strength of counter-rotating vortices. At high mean rise angle, the separation became stronger at the casing's first bend and moved farther upstream. At high ARs, a two-dimensional separation appeared on the casing and resulted in increased loss. Pressure loss penalties increased significantly with increasing duct mean rise angle and AR.

Inlet distortion often occurs under off-design conditions when a flow separates within an intake and this unsteady phenomenon can seriously impact fan performance. Fan–distortion interaction is a highly unsteady aerodynamic process into which high-fidelity simulations can provide detailed insights. However, due to limitations on the computational resource, the use of an eddy resolving method for a fully resolved fan calculation is currently infeasible within industry. To solve this problem, a mixed-fidelity computational fluid dynamics method is proposed. This method uses the large Eddy simulation (LES) approach to resolve the turbulence associated with separation and the immersed boundary method (IBM) with smeared geometry (IBMSG) to model the fan. The method is validated by providing comparisons against the experiment on the Darmstadt Rotor, which shows a good agreement in terms of total pressure distributions. A detailed investigation is then conducted for a subsonic rotor with an annular beam-generating inlet distortion. A number of studies are performed in order to investigate the fan's influence on the distortions. A comparison to the case without a fan shows that the fan has a significant effect in reducing distortions. Three fan locations are examined which reveal that the fan nearer to the inlet tends to have a higher pressure recovery. Three beams with different heights are also tested to generate various degrees of distortion. The results indicate that the fan can suppress the distortions and that the recovery effect is proportional to the degree of inlet distortion.

Current design-cycle Reynolds-averaged Navier–Stokes (RANS) based computational fluid dynamics (CFD) methods have the tendency to over-predict corner-stall events for axial-flow compressors operating at off-design conditions. This shortcoming has been demonstrated even in simple single-row cascade configurations. Here we report on the application of hybrid RANS/large eddy simulation (LES), or detached eddy simulation (DES), for simulating the corner-stall data from the linear compressor cascade work conducted at Ecole Centrale de Lyon. This benchmark data set provides detailed loss information while also revealing a bimodal behavior of the separation which, not surprisingly, is also not well modeled by RANS. The hybrid RANS/LES results presented here predict bimodal behavior similar to the data only when special treatment is adopted to resolve the leading-edge endwall region where the horseshoe vortex (HV) forms. The (HV) is shown to be unstable, which produces the bimodal instability. The DES simulation without special treatment or refinement in the HV region fails to predict the bimodal instability, and thus the bimodal behavior of the separation. This, in turn, causes a gross over-prediction in the scale of the corner-stall. The HV region is found to be unstable with rolling of the tertiary vortex (TV) over the secondary vortex and merging with the primary HV. With these flow dynamics realized in the DES simulations, the corner stall characteristics are found to be in better agreement with the experimental data, as compared to RANS and standard DES approaches.

Blade-to-blade interactions in a low-pressure turbine (LPT) were investigated using highly resolved compressible large eddy simulations (LESs). For a realistic setup, a stator and rotor configuration with profiles typical of LPTs was used. Simulations were conducted with an in-house solver varying the gap size between stator and rotor from 21.5% to 43% rotor chord. To investigate the effect of the gap size on the prevailing loss mechanisms, a loss breakdown was conducted. It was found that in the large gap (LG) size case, the turbulence kinetic energy (TKE) levels of the stator wake close to the rotor leading edge were only one third of those in the small gap (SG) case, due to the longer distance of constant area mixing. The small time-averaged suction side separation on the blade, found in the LG case, disappeared in the SG calculations, confirming how stronger wakes can keep the boundary layer attached. The higher intensity wake impinging on the blade, however, did not affect the time-averaged losses calculated using the control volume approach of Denton. On the other hand, losses computed by taking cross sections upstream and downstream of the blade revealed a greater distortion loss generated by the stator wakes in the SG case. Despite the suction side separation suppression, the SG case gave higher losses overall due to the incoming wake turbulent kinetic energy amplification along the blade passage.

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.