This two-part paper investigates the influence of rotor–stator interactions on the blade vibrational stresses of the first rotor, excited by the downstream stator. To this end, aeroacoustic and aeroelastic measurements and numerical setup studies for the solver TRACE are conducted in order to improve the predictive accuracy of blade vibrational stresses. Part I compares tip timing data for resonance crossings of three blisk modes to numerical predictions. Due to the single-row analysis within the linearized version of the flow solver TRACE, unsteady rotor–stator interactions are excluded by default. The findings show that leaving out these interactions in the numerical setup can lead to 97% lower vibrational stress predictions with respect to the absolute value measured. To validate the prediction of rotor–stator interactions by the nonlinear frequency domain method of TRACE, unsteady pressure measurements were conducted at the casing in the inter-row section of the first stage. The results were analyzed using an optimized measuring grid and applying a compressed sensing-based azimuthal mode analysis. Predicted azimuthal mode numbers are in accordance with the experiment, whereas amplitudes deviate from the measurements in part. Part II focuses on the prediction of blade vibrational stresses. To this end, a detailed grid study is performed and comparisons to steady and unsteady measurement data are made. In summary, this two-part paper confirms the importance of rotor–stator interactions for blade vibrational stresses excited by downstream vanes at a state-of-the-art high-pressure compressor.

Jet engines with boundary layer ingestion (BLI) could offer significant reductions in aircraft fuel burn compared with podded turbofans. However, the engine fans must run continuously with severe inlet distortion, which is known to reduce stability. In this paper, an experimental study has been completed on a low-speed rig fan operating with a BLI-type inlet distortion. Unsteady casing static pressure measurements have been made at multiple locations during stall events. Steady-state, full-annulus area traverses have also been performed at rotor inlet and exit at a near-stall operating point. The reduction in stability caused by BLI is found to be small. It is found that with BLI the fan can operate stably despite the presence of localized regions where the rotor operating point lies beyond the stability boundary measured in clean flow. With the BLI-type distortion applied, the measured rotor incidence varies around the annulus due to nonuniform upstream velocity and swirl. The measured amplitude of unsteady casing pressure fluctuations just prior to stall is found to correlate with the circumferential variation of rotor incidence, suggesting that rotor incidence is a key variable affecting the creation and growth of flow disturbances. In regions of high incidence, disturbances resembling local flow separations are initiated. However, in regions of low or negative incidence, any disturbances decay rapidly. Full rotating stall with BLI occurs when high incidence regions are widespread enough to sustain disturbances which can propagate around the entire annulus.

A further investigation of an acoustic theory-based stall-warning approach is presented in this paper, which contains the basis of this approach and an application on a low-speed compressor (LSC) with a stabilization system. In the present work, this stall-warning approach is first explained through a numerical simulation in which the periodicity of pressure signals is analyzed, and then application experiments of this approach are actualized on a LSC with a stall precursor-suppressed (SPS) casing treatment (CT) as a stabilization system. For this stall-warning approach, a parameter named Rc is calculated through pressure signals of compressor to evaluate the periodicity of pressure signal, and statistical estimates are implemented on Rc so that the probabilities for Rc less than a threshold Rc th can be used as a criterion for stall warning. The numerical and experimental results both show that the signal resolution is determined by the sensor position, the prestall signal amplitude decreases rapidly with the increase of the distance between sensor and blades. Results also show that the probability increases significantly when the operating point is nearing the stall boundary. And at the same operating point, the probability value of Rc will decrease when the SPS CT is engaged. Through this stall-warning approach, a stabilization system based on SPS CT can be activated when the stall margin needs to be extended.

This paper describes observed modal oscillations arising from a feedback mechanism between an acoustic resonance in the exit flow channel and aerodynamic and aeroelastic disturbances in a transonic fan stage. During tests, the fan suffered from rotating stall and surge which were preceded by low frequency pressure fluctuations. Through a range of aerodynamic and aeromechanical instrumentations, it was possible to determine a clear chain of cause and effect, whereby geometrical asymmetries trigger local instabilities and modal oscillations through an interaction with the system acoustics. To the authors knowledge, this is the first time that modal oscillations occurring before stall are attributed to multiphysical interactions, showing that acoustic characteristics of the system can influence the aerodynamic as well as the aeromechanical stability of fans. This bears implications for the stability assessment of fans and compressors because first, the stability margin may be affected by standing waves generated in bypass ducts or combustion chambers, and second, geometrical variations of the rotor blades which are believed to be beneficial for aeromechanical stability may lead to complex coupling phenomena.

Since the experiment in turbulence research is of very high importance for evaluating turbulence hypothesis, turbulence measurements were carried out in a two-stage two-spool transonic turbine test rig at the Institute for Thermal Turbomachinery and Machine Dynamics in Graz in which the two rotors are counter-rotating with two different rotational speeds. For the current measurement campaign, triple hot-wire probes, which represent a very new measurement technique in this test rig, were used and their results validated with a fast response aerodynamic pressure probe (FRAPP). Based on the data measured with this device, turbulence intensities may be determined using a method called Fourier filtering. If the classical ensemble averaging procedure with only one trigger is applied, the periodic fluctuations of the other rotor will artificially increase the stochastic fluctuations. Therefore, the two trigger signals of the two rotors require a special analysis method, which was established at Graz University of Technology. The results from this method will be compared to the classical triple decomposition, which uses only one trigger signal. With this analysis tool, it is not only possible to evaluate unsteady signals triggered by one of the two rotors, but also the unsteady interactions of the rotors can be determined and investigated.

Self-adaptive stability control with discrete tip air injection and online detection of prestall inception is experimentally studied in a low-speed axial flow compressor. The control strategy is to sense the cross-correlation coefficient of the wall static pressure patterns and to feed back the signal to an annular array of eight separately proportional injecting valves. The real-time detecting algorithm based on cross-correlation theory is proposed and experimentally conducted using the axisymmetric arrangement of time-resolved sensors. Subsequently, the sensitivity of the cross-correlation coefficient to the discrete tip air injection is investigated. Thus, the control law is formed on the basis of the cross-correlation as a function of the injected momentum ratios. The steady injection and the on–off pulsating injection are simultaneously selected for comparison. Results show that the proposed self-adaptive stability control using digital signal processing (DSP) controller can save energy when the compressor is stable. This control also provides protection when needed. With nearly the same stall margin improvement (SMI) as the steady injection (maximum SMI is 44.2%), the energy of the injected air is roughly a quarter of the steady injection. Unlike the on–off pulsating jet, the new actuating scheme can reduce the unsteady force impinging onto the compressor blades caused by the pulsating jets in addition to achieve the much larger stability range extension.

With the increase in computing power, large eddy simulation (LES) emerges as a promising technique to improve both knowledge of complex physics and reliability of turbomachinery flow predictions. However, these simulations are very expensive for industrial applications, especially when a 360 deg configuration should be considered. The objective of this paper is thus to adapt the well-known phase-lagged conditions to the LES approach by replacing the traditional Fourier series decomposition (FSD) with a compression method that does not make any assumptions on the spectrum of the flow. Several methods are reviewed, and the proper orthogonal decomposition (POD) is retained. This new method is first validated on a flow around a circular cylinder with rotating downstream blocks. The results show significant improvements with respect to the FSD. It is then applied to unsteady Reynolds-averaged Navier–Stokes (URANS) simulations of a single-stage compressor in 2.5D and 3D as a first validation step toward single-passage LES of turbomachinery configuration.

Detailed mapping of the sound field produced by a modern turbofan engine, with its multitude of overlapping noise sources, often requires a large number of microphones to properly resolve the directivity patterns of the constituent tonal and broadband components. This is especially true at high frequencies where the acoustic wavelength is short, or when shielding, scattering, and reflection of the sound field may be present due to installation effects. This paper presents a novel method for measuring the harmonic and broadband content of complex noncompact noise sources using continuously moving (referred to here as continuous-scan (CS)) microphones in conjunction with a state-of-the-art phase-referencing technique. Because the microphones are moving through the sound field produced by the noise sources, they effectively provide infinite spatial resolution of the sound directivity over the scan path. In this method, harmonic (i.e., shaft-coherent) content at the integer multiples of the instantaneous shaft rotational frequency is first extracted from the time signal using a tachometer signal and the Vold-Kalman (VK) filter. The residual broadband signal is then filtered in the time domain in fractional octave bands. The broadband spectra of the signals from the moving microphones are then computed at arbitrary positions along their scan paths using weighted averages (based on Chebyshev polynomial zero-crossings) and the assumption of a complex envelope that varies slowly over a spatial scale whose lower bound is set by the acoustic wavenumber. A benefit of this method is that the decomposition of the total measured sound field into a stochastic superposition of components preserves a meaningful phase definition for each “partial field” associated with a given shaft order (SO). This preservation of phase data enables the forward or backward projection of each of these partial fields using acoustical holography (AH). The benefits of the CS method are demonstrated using acoustic data acquired for a 22-in. scale-model fan stage run at the NASA Glenn Research Center's 9-foot by 15-foot wind tunnel. Two key outcomes of the work include (1) significant improvement in the spatial resolution of the measured sound field and (2) reduction in the overall data acquisition time. Additionally, the methods described here lead to new opportunities for noise source diagnostics and visualization.

Online line-of-sight (LOS) pyrometer is used on certain jet engines for diagnosis and control functions such as hot-blade detection, high-temperature limiting, and condition-based monitoring. Hot particulate bursts generated from jet engine combustor at certain running conditions lead to intermittent high-voltage signal outputs from the LOS pyrometer which is ultimately used by the onboard digital engine controller (DEC). To study the nature of hot particulates and enable LOS pyrometer functioning under burst conditions, a multicolor pyrometry (MCP) system was developed under DARPA funded program and tested on an aircraft jet engine. Soot particles generated as byproduct of combustion under certain conditions was identified as the root cause for the signal burst in a previous study. The apparent emissivity was then used to remove burst signals. In current study, the physics based filter with MCP algorithm using apparent emissivity was further extended to real-time engine control by removing burst signals at real time (1 MHz) and at engine DEC data rate. Simulink models are used to simulate the performances of the filter designs under engine normal and burst conditions. The results are compared with current LOS pyrometer results and show great advantage. The proposed model enables new LOS pyrometer design for improved engine control over wide range of operating conditions.

In this two-part paper, the phenomenon of part span rotating stall is studied. The objective is to improve understanding of the physics by which stable and persistent rotating stall occurs within high speed axial flow compressors. This phenomenon is studied both experimentally (Part I) and through the use of unsteady RANS simulations (Part II). In this paper, the behavior of an eight stage high speed compressor is studied during slow acceleration maneuvres along a fixed working line. Casing mounted pressure transducers and rotor mounted strain gages are used to examine the spectral content of any unsteadiness in the flow and its behavior across the operating range. By deliberate aerodynamic mismatching of the front stages through adjustment of three rows of variable stator vanes (VSVs), stable rotating stall is initiated. The observed behavior falls into two “families” of high and low frequency when tracked on the instrumentation. Further analysis based on the Doppler shift between the static and rotating measurements confirms that these respective phenomena are due to rotating stall of high and low cell count. Acoustic modes resulting from stall/rotor interaction are also identified. Strong correlation of the stall intensity with simple 1D meanline predicted loading parameters suggests that these families of behavior are independently linked to the stalling of different regions within the compressor.

This paper describes a wireless data transmission system for a large-scale rotating experiment to investigate the heat transfer in a three-passage serpentine test section. Patterned after the NASA HOST program, the current experiment extends the data set to larger aspect ratios including 1:2, 1:4, and 1:6. As with HOST, heat transfer is measured using the heated segments technique, and the serpentine test section spins at rotation numbers representative of engine conditions. Rotating experiments are essential for capturing the representative operating conditions and complicated flow physics that must be understood to advance internal cooling technology for high aspect ratio configurations. There are challenges associated with controlling the operating parameters and collecting accurate data for high measurement-density rotating experiments. This experiment requires that 140 copper panels be held at a constant temperature by independently controlling and recording the power supplied to a separate heater on each panel. This means there must be 140 temperature measurements, 140 pairs of heater power leads, enough power to drive all of these heaters, and data recording capacity left over to measure fluid temperatures and pressures. Traditional methods of transferring rotating signals to the stationary frame of reference (like slip rings) are widely implemented but have practical limitations in the quantity of transferrable signals and the electrical current capacity of the individual channels. Alternatively, wireless transmission techniques were first developed decades ago, but their practical use has been limited by onboard power delivery requirements and cost. This paper describes the development of a new data transmission and control system that takes advantage of improvements in inexpensive electronics to create a battery-powered and microprocessor controlled system for acquisition, storage, control, and wireless communication. These components are assembled as an integral part of the rotating mechanical hardware. By handling high-fidelity microcircuit signal conditioning, data acquisition, feedback control, and data storage in the rotating frame and transmitting the results wirelessly, this system provides high measurement density and active feedback control that would have been impractical with a conventional slip-ring approach. The design and construction of the wireless control system for one full sidewall of the three-serpentine passage is described in detail. Its capability and functionality is demonstrated with operational data. It will be demonstrated that while all of the components in this system are readily available, the unique combination of this technology opens up a new world of measurement capabilities.

A Defense Advanced Research Projects Agency (DARPA)-funded multicolor pyrometry (MCP) experiment was carried out on a government-provided aircraft engine to study the nature of hot particulate bursts generated from the combustor at certain engine conditions. These bursts of hot particulates lead to intermittent high-voltage signal output from the line-of-sight (LOS) pyrometer that is ultimately detected and used by the onboard digital engine controller (DEC). The investigation used a high-speed MCP system designed to detect bursts and identify their properties. Results of the radiant temperature, multicolor temperature, and apparent emissivity are presented. The results indicated that the apparent emissivity calculated during the signal burst was lower than that of the blade. The root cause for the signal burst was identified as soot particles generated as a by-product of combustion under certain conditions. This conclusion was drawn based on both experimental and simulation results. Technical strategies to separate, reduce, or remove the burst signal are proposed.

Transient casing pressure data from a transonic rotor and rotor-stator stage measured using high-speed pressure probes embedded in the casewall over the rotor tips are analyzed. Using long data sets sampled at a high frequency, low-frequency (less than once-per-revolution) nonaxisymmetric flow phenomena were detected while operating at steady-state conditions near stall. Both the rotor and stage cases are investigated, and the difference in behavior of a rotor with and without a stator blade row is investigated. Data for both cases over the speed range 70–100% of design and from choke to near the stability limit (stall or surge) are presented. The root mean square power of the low-frequency signal as well as its fraction of the total pressure signal is presented. It was thought that the behavior of these signals as stall was approached could lead to some method of detecting the proximity of stall. For the rotor-only configuration, the strength of these nonaxisymmetric phenomena increased as stall was approached for all speed-lines. However, for the stage configuration, more representative of an operational machine, these were of a lower magnitude and did not exhibit a clearly increasing trend as stall was approached. This would seem to indicate that the stator suppressed these signals somewhat. It is also shown that these nonaxisymmetric phenomena led to a significant variation of the mean relative inlet flow angle into the rotor blade. During stable operation near to stall at 100% speed for the rotor-only case, a 1.9 deg variation of this angle was measured. This compared with a 5.6 deg variation over the entire speed-line. Further, it was observed that while the rotor and stage cases had different stability limits, their peak relative inlet flow angles near stall were similar for both along most speed-lines.

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.

Rig and engine test processes and in-flight operation and safety for modern gas turbine engines can be greatly improved with the development of accurate on-line measurement to gauge the aerodynamic stability level for fans and compressors. This paper describes the development and application of a robust real-time algorithm for gauging fan/compressor aerodynamic stability level using over-the-rotor dynamic pressure sensors. This real-time scheme computes a correlation measure through signal multiplication and integration. The algorithm uses the existing speed signal from the engine control for cycle synchronization. The algorithm is simple and is implemented on a portable computer to facilitate rapid real-time implementation on different experimental platforms as demonstrated both on a full-scale high-speed compressor rig and on an advanced aircraft engine. In the multistage advanced compressor rig test, the compressor was moved toward stall at constant speed by closing a discharge valve. The stability management system was able to detect an impending stall and trigger opening of the valve so as to avoid compressor surge. In the full-scale engine test, the engine was configured with a one-per-revolution distortion screen and transients were run with a significant amount of fuel enrichment to facilitate stall. Test data from a series of continuous rapid transients run in the engine test showed that in all cases, the stability management system was able to detect an impending stall and manipulated the enrichment part of the fuel schedule to provide stall-free transients.

A new, computationally efficient method is presented for processing transient thin-film heat transfer gauge signals. These gauges are widely used in gas turbine heat transfer research, where, historically, the desired experimental heat transfer flux signals, q , are derived from transient measured surface-temperature signals, T , using numerical approximations to the solutions of the linear differential equations relating the two. The new method uses known pairs of exact solutions, such as the T response due to a step in q , to derive a sampled approximation of the impulse response of the gauge system. This impulse response is then used as a finite impulse response digital filter to process the sampled T signal to derive the required sampled q signal. This is computationally efficient because the impulse response need only be derived once for each gauge for a given sample rate, but can be reused repeatedly, using optimized MATLAB filter routines and is highly accurate. The impulse response method can be used for most types of heat flux gauge. In fact, the method is universal for any linear measurement systems which can be described by linear differential equations where theoretical solution pairs exist between input and output. Examples using the new method to process turbomachinery heat flux signals are given.

A novel heat flux sensor was tested that allows for time-resolved heat flux measurements in internal ribbed channels related to the study of passages in gas turbine blades. The working principle of the atomic layer thermopile (ALTP) sensor is based on a thermoelectric field created by a temperature gradient over an yttrium-barium-copper-oxide (YBCO) crystal (the transverse Seebeck effect). The sensors very fast frequency response allows for highly time-resolved heat flux measurements up to the 1 MHz range. This paper explains the design and working principle of the sensor, as well as the benchmarking of the sensor for several flow conditions. For internal cooling passages, this novel sensor allows for highly accurate, time-resolved measurements of heat transfer coefficients, leading to a greater understanding of the influence of fluctuations in temperature fields.

Predictions of time-resolved flowfields are now commonplace within the gas-turbine industry, and the results of such simulations are often used to make design decisions during the development of new products. Hence it is necessary for design engineers to have a robust method to determine the level of convergence in design predictions. Here we report on a method developed to determine the level of convergence in a predicted flowfield that is characterized by periodic unsteadiness. The method relies on fundamental concepts from digital signal processing including the discrete Fourier transform, cross correlation, and Parseval’s theorem. Often in predictions of vane–blade interaction in turbomachines, the period of the unsteady fluctuations is expected. In this method, the development of time-mean quantities, Fourier components (both magnitude and phase), cross correlations, and integrated signal power are tracked at locations of interest from one period to the next as the solution progresses. Each of these separate quantities yields some relative measure of convergence that is subsequently processed to form a fuzzy set. Thus the overall level of convergence in the solution is given by the intersection of these sets. Examples of the application of this technique to several predictions of unsteady flows from two separate solvers are given. These include a prediction of hot-streak migration as well as more typical cases. It is shown that the method yields a robust determination of convergence. Also, the results of the technique can guide further analysis and∕or post-processing of the flowfield. Finally, the method is useful for the detection of inherent unsteadiness in the flowfield, and as such it can be used to prevent design escapes.

This paper proposes a unique stall risk index based on pressure signals by high-response transducers on the casing wall at the rotor leading-edge location. The aim of the research is to explore the possibility of reducing current excessive stall margin requirement for compressor design based on the worst-case scenario. The index is generated by computing correlation degradation of pressure time histories of current and one revolution before over each blade pitch. Tests conducted on a single-stage low-speed compressor exhibits that the correlation diminishes significantly with proximity to stall, and the proposed technique might have the capability of generating a stall warning signal sufficiently in advance of spike inception. Extensive experiments on a research compressor show that the degree of the index degradation depends on various factors, such as flow coefficient, tip clearance, and rotor blade incidence. In order to obtain a reliable stall warning signal in practical use, these effects must be carefully examined.

Five high-speed compressor configurations are used to identify pre-stall pressure signal activity under clean and distorted inlet conditions, and under steady injection and controlled injection conditions. Through the use of a nonlinear statistic called correlation integral, variations in the compressor dynamics are identified from the pre-stall pressure activity far before variations (modal or pip) are observed visually in the wall static pressure measurements. The correlation integral not only discerns changing dynamics of these compressors prior to stall, but is now used to measure the strength of the tip flow field for these five high-speed compressors. Results show that correlation integral value changes dramatically when the stall inception is modal; and it changes less severely when the stall inception is through pip disturbances. This algorithm can therefore distinguish from the pre-stall pressure traces when a machine is more likely to stall due to pips versus modes. When used in this manner, the correlation integral thus provides a measure of tip flow strength. The algorithm requires no predisposition about the expected behavior of the data in order to detect changing dynamics in the compressor; thus, no pre-filtering is necessary. However, by band-pass filtering the data, one can monitor changing dynamics in the tip flow field for various frequency regimes. An outcome of this is to associate changes in correlation integral value directly with frequency specific events occurring in the compressor, i.e., blade length scale events versus long length scale acoustic events. The correlation integral provides a potential advantage over linear spectral techniques because a single sensor is used for detection and analysis of the instabilities.