Experiment on Adiabatic Film Cooling Effectiveness in Front Zone of Effusion Cooling Configuration

Experimental investigation is performed to investigate the cooling characteristics in the front zone of effusion configuration. Effects of blowing ratio,multi-hole arrangement mode,hole-to-hole pitch and jet orientation angle on the adiabatic film cooling effectiveness are concentrated on. The results show that the film layer displays an obvious"developing"feature in the front zone of effusion cooling scheme,for either the staggered or inline multi-hole arrangement. The varying gradient of the laterally-averaged adiabatic cooling effectiveness along the streamwise direction is greater for the staggered arrangement than that for the inline arrangement. The holes array arranged in staggered mode with small hole-tohole pitches is in favor of obtaining developed film coverage layer rapidly.

Energy saving analysis of a transparent radiative cooling film for buildings with roof glazing

A transparent radiative cooling(T-RC)film with low transmittance in solar spectra and selectively high emissivity in the atmospheric window(8-13𝜇m)is applied on roof glazing for building energy saving.To evaluate the per-formance of the T-RC film,two identical model boxes(1.0 m×0.6 m×1.2 m,L×W×H)were constructed and the inside air temperatures were measured in August in Ningbo,China.Results show that the maximum temperature difference between the two model boxes with and without the T-RC film was 21.6℃during the experiment.A whole building model was built in EnergyPlus for the model box.With a good agreement achieved between the calculation results and the measured temperature data,the experimentally validated EnergyPlus model was then extended to an 815.1 m^(2)exhibition building with roof glazing to analyze the annual air conditioning(AC)energy consumption.The results show that by incorporating both the T-RC film’s cooling benefit in summer and heating penalty in winter,the annual AC energy consumption of the exhibition building can be reduced by 40.9-63.4%,varying with different climate conditions.

Large Eddy Simulation of the Effects of Plasma Actuation Strength on Film Cooling Efficiency

In this article, numerical investigation of the effects of different plasma actuation strengths on the film cooling flow characteristics has been conducted using large eddy simulation(LES). For this numerical research, the plasma actuator is placed downstream of the trailing edge of the film cooling hole and a phenomenological model is employed to provide the electric field generated by it, resulting in the body forces. Our results show that as the plasma actuation strength grows larger, under the downward effect of the plasma actuation, the jet trajectory near the cooling hole stays closer to the wall and the recirculation region observably reduces in size. Meanwhile, the momentum injection effect of the plasma actuation also actively alters the distributions of the velocity components downstream of the cooling hole. Consequently, the influence of the plasma actuation strength on the Reynolds stress downstream of the cooling hole is remarkable. Furthermore, the plasma actuation weakens the strength of the kidney shaped vortex and prevents the jet from lifting off the wall. Therefore, with the increase of the strength of the plasma actuation, the coolant core stays closer to the wall and tends to split into two distinct regions. So the centerline film cooling efficiency is enhanced, and it is increased by 55% at most when the plasma actuation strength is 10.

Numerical study of wave disturbance in liquid cooling film

Transient numerical simulations are carried out to investigate the liquid-gas interfacecharacteristics associated with liquid film cooling flows.A two-dimensional axisymmetricmulti-phase numerical model using finite volume formulation is developed.The model hasbeen validated against available experimental data for liquid-film cooling flows inside tubes.The model has been used to predict the interface characteristics for a variety of imposedparameters and momentum flux ratios under cold flow conditions wherein both the coolant andmainstream are maintained at the same temperature.Disturbance waves are observed at theliquid-gas interface for coolant flows above a critical value and after a finite distance from theinlet.The distance toward the wave inception point increased with the increase of momentumflux ratio.However,at higher momentum flux ratios,the properties of the disturbance wavesdid not vary significantly.The parameters related to the liquid-gas interface waves,namely,wave velocity,frequency,amplitude and wave length have been analyzed in detail.Analysisindicates that the liquid entrainment is due to the shearing of the disturbance wave crest.

Numerical investigation of unsteady mixing mechanism in plate film cooling

A large-scale large eddy simulation in high performance personal computer clusters is carried out to present unsteady mixing mechanism of film cooling and the development of films.Simulation cases include a single-hole plate with the inclined angle of 30° and blowing ratio of 0.5,and a single-row plate with hole-spacing of 1.5D and 2D(diameters of the hole).According to the massive simulation results,some new unsteady phenomena of gas films are found.The vortex system is changed in different position with the development of film cooling with the time marching the process of a single-row plate film cooling.Due to the mutual interference effects including mutual exclusion,a certain periodic sloshing and mutual fusion,and the structures of a variety of vortices change between parallel gas films.Macroscopic flow structures and heat transfer behaviors are obtained based on 20 million grids and Reynolds number of 28600.

Hybrid RANS-LES of Shaped Hole Film Cooling on an Adiabatic Flat Plate at Low Reynolds Number

Hybrid RANS-LES methods offer a means of reducing computational cost and setup time to simulate transitional flows. Several methods are evaluated in ANSYS CFX, including Scale-Adaptive Simulation (SAS), Shielded Detached Eddy Simulation (SDES), Stress-Blended Eddy Simulation (SBES), and Zonal Large Eddy Simulation (ZLES), along with a no-model laminar simulation. Each is used to simulate an adiabatic flat plate film cooling experiment of a shaped hole at low Reynolds number. Adiabatic effectiveness is calculated for Blowing Ratio (BR) = 1.5 and Density Ratio (DR) = 1.5. The ZLES method and laminar simulation most accurately match experimental lateral-average adiabatic effectiveness along the streamwise direction from the trailing edge of the hole to 35 hole diameters downstream of the hole (X/D = 0 to X/D = 35), with RMS deviations of 5.1% and 4.2%, and maximum deviations of 8% and 11%, respectively. The accuracy of these models is attributed to the resolution of turbulent structures in not only the mixing region but in the upstream boundary layer as well, where the other methods utilize RANS and do not switch to LES.

Flow Visualization of Multi-Hole Film-Cooling Flow under Varying Freestream Turbulence Levels

A flat plate film cooling flow from a multi-exit hole configuration has been numerically simulated using both steady and unsteady Reynolds Averaged Navier Stokes (RANS and URANS) Computational Fluid Dynamics (CFD) formulations. This multi-exit hole concept, the Anti-Vortex Hole (AVH), has been developed and studied by previous research groups and shown to mitigate or counter the vorticity generated by conventional holes resulting in a more attached film cooling layer and higher film cooling effectiveness. The film cooling jets interaction with the free stream flow is a long studied area in gas turbine heat transfer. The present study numerically simulates the jet interaction with the multi-exit hole concept at a high blowing ratio (M = 2.0) and density ratio (DR = 2.0) in order to provide a more detailed, graphical explanation of the improvement in film cooling effectiveness. This paper presents a numerical study of the flow visualization of the interaction of film cooling jets with a subsonic crossflow. The contour plots of adiabatic cooling effectiveness were used to compare the multi-exit hole and conventional single hole configurations. The vortex structures in the flow were analyzed by URANS formulations and the effect of these vortices on the cooling effectiveness was investigated together with the coolant jet lift-off predictions. Quasi-Instantaneous Temperature Isosurface plots are used in the investigations of the effect of turbulence intensity on the cooling effectiveness and coolant jet coverage. The effect of varying turbulence intensity was investigated when analyzing the jets’ interaction with the cross flow and the corresponding temperatures at the wall. The results show that as the turbulence intensity is increased, the cooling flow will stay more attached to the wall and have more pronounced lateral spreading far downstream of the cooling holes.

Analysis of Film Cooling Effectiveness on Shaped Hole and Antivortex Hole

Film cooling is introduction of a secondary fluid (coolant or injected fluid) at one or more discrete locations along a surface exposed to a high temperature environment to protect that surface not only in the immediate region of injection but also downstream region. This paper numerically investigated the film cooling effectiveness on two types of hole geometries which are cut-shaped hole and antivortex hole. The 3D computational geometries are modeled with a single 30 deg angled hole on a flat surface. The different blowing ratios of 0.5,1,1.5,2,2.5,3,3.5,4,4.5,5 and k-Epsilon turbulence model are used in this study. A two dimensional distribution of film cooling effectiveness in the downstream region of the cooling hole is performed. A comparison of spanwise averaged effectiveness is also performed in the field starts from center point of hole to X/D=30.

Experimental Study on the Film Cooling Characteristics of Three Complex Tip Structures

The turbine blades of aircrafts must be properly cooled to prevent engine failure.Thus,to investigate the influence of the tip structure on the film cooling effect,pressure-sensitive paint test technology was used to determine the adiabatic film cooling effectiveness in this study.The experiment was completed in a cascade comprising three straight blades.The effects of the blowing ratio,density ratio,tip clearance,and tip structure on film cooling efficiency were analyzed.The experimental results demonstrated that,as the blowing ratio increased,the film coverage area and film cooling efficiency increased under most experimental conditions.However,the film cooling efficiency was found to initially increase,and subsequently decrease,as the blowing ratio increased.The respective influences of the density ratio and tip clearance on the film cooling efficiency were found to be significant.The density ratio experiments revealed that a high-density ratio can result in better film coverage than the low-density-ratio air.The tip clearance experimental results indicated that a small tip clearance promotes an increase in film cooling efficiency;this is because the small tip clearance negatively affects the main stream leakage flow,which can reduce the film coverage area.Under the conditions of the Base case 2 configuration,a blowing ratio of 2.1,and a tip clearance of 0.6%h,the average film cooling efficiency of the blade tip was 0.22.Among the three blade tip structures applied in this study,Base case 2 demonstrated higher film cooling efficiency than the other two blade tip structures under the conditions of the same blowing ratio,tip clearance,and density ratio.

Investigation of Interacting Mechanism between Film Cooling and Internal Cooling Structures of Turbine Blade

This paper presents three-dimensional numerical simulations with the established realizable k-εmodel to clarify the underlying and interacting mechanisms between the film cooling and the internal cooling.On the one hand,the effects of three different internal cooling channels,i.e.,smooth channel,continuous ribbed channel,and truncated ribbed channel,on the film cooling effectiveness and the discharge coefficients are investigated.On the other hand,the influences of three different film cooling holes,i.e.,cylindrical hole,two elliptical holes and two circular-to-elliptical holes,on the heat transfer performances and pressure loss of the internal cooling channel are revealed.Especially,the suction effects of the film cooling holes are analyzed through setting up baselines with only internal cooling channels.Results show that the placement of ribs in the internal channel has different influences on the film cooling effectiveness with respect to different hole shapes depending on the blowing ratio.The discharge coefficient of the film hole can be improved by introducing ribs to the internal channel.Suction of film hole is helpful for enhancing the heat transfer performance and reducing the pressure loss of the internal channel.Besides,ribs instead of the suction effect of film hole play a major role to enhance the heat transfer performance in the internal cooling channel.

Effects of plasma actuation and hole configuration on film cooling performance

In this paper,plasma actuators are arranged asymmetrically downstream the wall to improve film cooling performance.Effects of blowing ratio,hole configuration and applied voltage on flow characteristics and film cooling effectiveness were investigated numerically on a flat plate.Results show that highest film cooling effectiveness distribution is obtained both in the spanwise and streamwise directions under blowing ratio of 0.5.Average wall film cooling effectiveness of cylindrical hole increases by 251.9%under blowing ratio of 0.5 compared to that under blowing ratio of 1.5.The scale of the counter rotating vortex pairs(CRVP)from fan shaped hole and sister hole are significantly reduced compared to that from cylindrical hole.The console hole has an anti-counter rotating vortex pair(Anti-CRVP),which weakens the entrainment of the CRVP to the coolant air near the wall.Compared with the cylindrical hole,average wall film cooling effectivenesses for fan shaped hole,sister hole and console hole increase by 73.1%,97.5%and 119.9%.The adherent performance of the coolant air is enhanced after applying plasma actuator.The aerodynamic actuation of the plasma results in the rebound of the fluid close to the wall at 24 kV applied voltage.Average wall film cooling effectiveness of the console hole at 12 kV applied voltage is 10.6%higher than that without plasma.

Experimental Study of Heat Transfer and Film Cooling Performance of Upstream Ejected Coolant on a Turbine Endwall

An upstream coolant injection that is different from the known leakage flow was introduced to protect the turbine endwall.This coolant is ejected tangentially from a row of cylindrical holes situated at the side of a backward-facing step.In this experiment,the effects of mass flow ratio and leakage slot width on the endwall heat transfer characteristics were investigated.The dimensionless heat transfer coefficient(Nu)and adiabatic film cooling effectiveness(η)on an axisymmetric turbine endwall were measured by the stable-state thermochromic liquid crystal(TLC)technique and the pressure sensitive paint(PSP)technique,respectively.Three mass flow ratios(MFR)of 0.64%,0.85%,and 1.07%,as well as two leakage slot widths(W)of 3.93 mm,and 7.86 mm were considered.Results indicate that the injection film suppresses the strength of the passage vortex,which leads to the coolant covering almost the entire endwall.This result is more evident for the higher MFR cases,meanwhile,the corresponding averaged film cooling effectiveness is increased with the enhancement of the MFR.However,the case with a higher MFR produces a higher heat transfer coefficient distribution,especially in the region close to the leakage slot edge.Besides,when the W is lower,the endwall presents a higherηand a lower Nu for all the cases,which can guide the optimal design of the endwall.

Stage identification and process optimization for fast drilling EDM of film cooling holes using KBSI method

Fast drilling electrical discharge machining(EDM)is widely used in the manufacture of film cooling holes of turbine blades.However,due to the various hole orientations and severe electrode wear,it is relatively intricate to accurately and timely identify the critical moments such as breakout,hole completion in the drilling process,and adjust the machining strategy properly.Existing breakout detection and hole completion determination methods are not suitable for the high-efficiency and fully automatic production of film cooling holes,for they almost all depend on preset thresholds or training data and become less appropriate when machining condition changes.As the breakout and hole completion detection problems can be abstracted to an online stage identification problem,in this paper,a kurtosis-based stage identification(KBSI)method,which uses a novel normalized kurtosis to denote the recent changing trends of gap voltage signals,is developed for online stage identification.The identification accuracy and generalization ability of the KBSI method have been verified in various machining conditions.To improve the overall machining efficiency,the influence of servo control parameters on machining efficiency of each machining stage was analyzed experimentally,and a new stage-wise adaptive control strategy was then proposed to dynamically adjust the servo control parameters according to the online identification results.The performance of the new strategy is evaluated by drilling film cooling holes at different hole orientations.Experimental results show that with the new control strategy,machining efficiency and the machining quality can be significantly improved.

Recent advances in film cooling enhancement:A review

Film cooling is an indispensable scheme in the design of highly-efficient cooling configurations to satisfy the thermal protection requirement of turbine hot section components.During the last few decades,vast efforts have been paid on the discrete-hole film cooling enhancement.In this paper,some of the recent literatures related to the passive strategies(such as shaped film cooling holes,upstream ramps,shallow trenches,mesh-fed slots)and the active strategies(such as the use of pulsation modulating device or plasma actuator)for film cooling enhancement are surveyed,with the aim at presenting an updated overview about the state of the art in advanced film cooling.In addition,some challenging issues are also outlined to motivate further investigations in such a broad topic.

Equivalent model of close-packed film cooling holes in nickel-based single crystal cooled blade based on crystallographic theory

The mechanical properties of nickel-based single crystal thin-walled plate with close-packed film cooling holes were studied based on the equivalent solid material concept. The effective plastic parameters inversion method based on crystallographic theory were proposed. A simplification method for close-packed film cooling hole plates with square and triangular penetration patterns was presented. A large number of finite element analysis results covering different ligament efficiencies and penetration patterns were provided to verify the feasibility of the plastic equivalent principle and simplification method. The results show that the stress–strain curve and resolved shear stresses of simplification models are in consistence with the plate models with close-packed film cooling holes. The equivalent errors of yield strength are all within the error band and the values of equivalent errors are all less than 10%. In addition, the equivalent errors of the positions where maximum resolved shear stress occurs are all less than 15°, indicating the accuracy of plastic equivalent model and simplification method.

Influence of shock wave impinging region on supersonic film cooling

Shock waves can significantly affect the film cooling for supersonic flow and shock waves may have different influence when impinging in different regions.The present study numerically compared the results of shock wave impinging in three different regions and analyzed the effect of impinging region.The shock wave generators were located at x/s=5,25,45 with 4°,7°and 10°shock wave incidence.The mainstream Mach number was 3.2 and the coolant Mach number was 1.2 or 1.5.The numerical results illustrated that the shock wave impinged in the further upstream region led to a larger high-pressure region and a larger vortex in the boundary layer.Moreover,placing the shock wave generator upstream resulted in the lower mass fraction of coolant in the downstream region.The velocity in the upstream part of the cooling layer was lower than the midstream and downstream part,which resulted in the less ability to resist the shock wave impingement.Therefore,the upstream impingement deteriorated the cooling performance to a greater extent.The study also manifested that the stronger shock wave had a larger effect on supersonic film cooling.Increasing the coolant inlet Mach number can increase the blowing ratio and reduce the mixing,which was of benefit to improve cooling effect.

Experiments on film cooling with sonic injection into a supersonic flow

Film cooling experiments with sonic injection were conducted to investigate the effects of the number of the injection holes,the mass flow ratio,and the hole spacing on the film cooling effectiveness.The mainstream was obtained by the hydrogen-oxygen combustion,entering the experimental section at a Mach number of 2.0.The nitrogen with ambient temperature was injected into the experimental section at a sonic speed.The measured mainstream recovery temperature was approximately 910K.The mass flow ratio was regulated by varying the nitrogen injection pressure.The experimental results show that for the investigated cooling surface,the cooling effectiveness increases with the increase in the number of the injection holes with other parameters held constant.For a fixed cooling configuration,the cooling effectiveness increases with the increase in the mass flow ratio.Different from the subsonic film cooling,the optimal mass flow ratio is not observed.When the hole spacing is less than 4,no obvious difference is observed on the cooling effectiveness and lateral uniformity.With the mass flow ratio increasing further,this difference becomes much smaller.The shock wave also has an effect on the cooling effectiveness.Downstream the incident point of the shock wave,the cooling effectiveness is lower than that in the case without the shock wave.

Improvement on shaped-hole film cooling effectiveness by integrating upstream sand-dune-shaped ramps

A numerical investigation and experimental validation is performed to address deeper insights into the combined effect of shaped holes and Sand-Dune-shaped upstream Ramp(SDR)on enhancing the film cooling effectiveness,under a wide blowing ratio range(M=0.25–1.5).Three kinds of holes(Cylindrical Hole(CH),Fan-Shaped Hole(FSH),and Crater-Shaped Hole(CSH))are taken into consideration.The SDR shows an inherent affecting mechanism on the mutual interaction of jet-in-crossflow.It aggravates the lateral spreading of cooling jet and thus improves the film cooling uniformity significantly,regardless of film-hole shape and blowing ratio.When the blowing ratio is beyond 1.0,the combined effect of shaped holes and SDR on improving film cooling effectiveness behaves more significantly.It is suggested that FSH-SDR is a most favorable film cooling scheme.For FSH-SDR case,the spatially-averaged film cooling effectiveness is increased monotonously with the increase of blowing ratio,among the present bowing ratio range.

Numerical Simulation Study on Cooling Characteristics of a New Type of Film Hole

A new type of film cooling hole with micro groove structure is presented in this paper.Based on the finite volume method and the Realizable k-εmodel,the film cooling process of the hole in a flat plate structure is simulated.The surface temperature distribution and film cooling effect of different film cooling holes were analyzed.The effects of micro-groove structure on wall attachment and cooling efficiency of jet were discussed.The results show that under the same conditions,the transverse coverage width and overall protective area of the new micro-groove holes are larger than those of the ordinary cylindrical holes and special-shaped holes.Compared with ordinary holes,the new micro-groove holes can better form the film covering on the surface and enhance the overall film cooling efficiency of the wall.For example,when the blowing ratio M=1.5,the effective coverage ratio of micro-groove holes is 1.5 times the dustpan holes and is 8 times the traditional cylindrical holes.It provides reference data and experience rules for the optimization and selection of advanced cooling structure of high performance aero-gas engine hot-end components.

Review on film coolingofliquidrocketengines

Film cooling in combination with regenerative cooling is presently considered as an efficient method to guarantee safe operation of liquid rocket engines having higher heat flux densities for long duration.This paper aims to bring all the research carried out in the field of liquid rocket engine film cooling since 1950.The analytical and numerical procedure followed,experimental facilities and measurements made and major inferences drawn are reviewed in detail,and compared where ever possible.Review has been made through a discussion of the analyses methodologies and the factors that influence film cooling performance.An effort has also been made to determine the status of the research,pointing out critical gaps,which are still to be explained and addressed by future generations.