Conjugate Heat Transfer Investigation on the Cooling Performance of Air Cooled Turbine Blade with Thermal Barrier Coating

A hot wind tunnel of annular cascade test rig is established for measuring temperature distribution on a real gas turbine blade surface with infrared camera.Besides,conjugate heat transfer numerical simulation is performed to obtain cooling efficiency distribution on both blade substrate surface and coating surface for comparison.The effect of thermal barrier coating on the overall cooling performance for blades is compared under varied mass flow rate of coolant,and spatial difference is also discussed.Results indicate that the cooling efficiency in the leading edge and trailing edge areas of the blade is the lowest.The cooling performance is not only influenced by the internal cooling structures layout inside the blade but also by the flow condition of the mainstream in the external cascade path.Thermal barrier effects of the coating vary at different regions of the blade surface,where higher internal cooling performance exists,more effective the thermal barrier will be,which means the thermal protection effect of coatings is remarkable in these regions.At the designed mass flow ratio condition,the cooling efficiency on the pressure side varies by 0.13 for the coating surface and substrate surface,while this value is 0.09 on the suction side.

Heat Transfer and Flow Structure of a Turbine Blade's Air-cooled Leading Edge Considering Different Hole Shapes and Additional Flow Angles

A numerical study is conducted to elucidate the impact of hole shapes and additional flow angles on the flow structure of the coolant and temperature field in the leading edge area of the gas turbine rotor.Four typical hole shapes are considered for the GE-E3 blade.The impact of the additional flow angle(E)within each hole shape on the temperature field is investigated.The results indicate that for the leading edge area and suction surface,the fan-shaped hole case performs best in decreasing temperatures,with a decrease of about 43 K.This is mainly due to the fact that the fan-shaped hole has the maximum expansion in hole spanwise direction.For the pressure surface,the console hole case performs best in decreasing temperatures,with a maximum reduction of about 47.2 K.The influence of E on the surface temperature at leading edge area varied between the different hole shapes.For the cylinder hole and console hole,the E=-20°case has the lowest area-averaged temperature.Because both the fan-shaped hole and the 7-7-7 shaped hole are expansion holes,the pattern of variation of the leading edge area temperature with increasing E is similar for the fan-shaped hole case and 7-7-7 shaped hole case.The E=20°case shows the lowest spanwise-averaged temperature near the hole outlet,and the E=-20°case shows the lowest spanwise-averaged temperature further downstream.

A review of recent studies on rotating internal cooling for gas turbine blades

Gas turbines have been used extensively for aircraft and marine propulsions as well as land-based power generation because of their high thermal efficiency and large power to weight ratios.To further increase the thermal efficiency,numerous prior researches on gas turbine blade internal cooling have been intensively carried out,majorly under stationary conditions.However,the stationary studies neglect the effects of Coriolis and buoyancy forces,which should change the velocity,turbulence and temperature distribution under rotating conditions.To elucidate the rotational effects on gas turbine internal cooling,the extensive results collected from recent investigations are discussed,which include the rotation and buoyancy effects on the rib turbulated cooling,pin fin cooling,jet impingement cooling,dimple/protrusion cooling,latticework cooling as well as swirl cooling.The rotational effects on the friction factors and the most employed experimental and numerical methods are also presented.Moreover,recommendations for future research are outlined.Therefore,this review article provides extensive literature information for the design of the next-generation high-efficiency internal cooling for rotating turbine blades.

Influences of Hole Shape on Film Cooling Characteristics with CO_2 Injection

This article presents the data about heat transfer coefficient ratios, film cooling effectiveness and heat loads for the injection through cylindrical holes, 3-in-1 holes and fanned holes in order to characterize the film cooling performance downstream of a row of holes with 45° inclination and 3 hole spacing apart. The trip wire is placed upstream at a distance of 10 times diameter of the cooling hole from the hole center to keep mainstream fully turbulent. Both inlet and outlet of 3-in-1 holes have a 15° lateral expansion. The outlet of fanned holes has a lateral expansion. CO2 is applied for secondary injection to obtain a density ratio of 1.5. Momentum flux ratio varies from 1 to 4. The results indicate that the increased momentum flux ratio significantly increases heat transfer coefficient and slightly improve film cooling effectiveness for the injection through cylindrical holes. A weak dependence of heat transfer coefficient and film cooling effectiveness, respectively, on momentum flux ratio has been identified for the injection through 3-in-1 holes. The in- crease of the momentum flux ratio decreases heat transfer coefficient and significantly increases film cooling effectiveness for the injection through fanned holes. In terms of the film cooling performance, the fanned holes are the best while the cylindrical holes are the worst among the three hole shapes under study.

Comparative Study on Different Methods for Prediction of Thermal Insulation Performance of Thermal Barrier Coating Used on Turbine Blades

As turbine inlet temperature gets higher and higher,thermal barrier coating(TBC) is more and more widely used in turbine blades.For turbine blades with TBC,it is of great significance to evaluate the temperature distribution of its substrate metal quickly and accurately,especially during the design stage.With different degrees of simplification such as whether to consider the change of the geometric size of the fluid domain by TBC and whether to consider the planar heat conduction in TBC,three different methods used in conjugate heat transfer(CHT) simulation to model the TBC of the turbine blades have been developed and widely used by researchers.However,little research has been conducted to investigate the influence of the three methods on the temperature distribution of turbine blade.To fill this gap,three geometric models were designed.They are a solid conduction model with a substrate metal layer and a TBC layer,a transonic turbine vane with internal cooling and TBC,and a plate cylindrical film hole cooling model with TBC.Different methods were used in these geometric models and their differences were carefully analyzed and discussed.The result shows that for the conduction model used in this paper,with the same TBC surface temperature distribution,the difference between the three methods is very small and can be ignored.For a transonic turbine vane with internal cooling,regarding the local maximum temperature of the substrate-TBC interface,the largest difference between the method in which TBC is considered as a thermal resistance or a virtual layer of cells and the method in which three-dimensional heat conduction equation of TBC is solved occurs at the trailing edge.The difference near the leading edge is below 2K.When employed to the film cooling model,the difference of the laterally averaged temperature of the substrate-TBC interface can be 8 K which is mainly due to the change of the length to diameter ratio of the film cooling hole by TBC.If the substrate thickness is reduced by the thickness of TBC when three-dimensional heat conduction equation of TBC is solved,the temperature difference between the three methods will be quite limited.

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.

Gas film/regenerative composite cooling characteristics of the liquid oxygen/liquid methane (LOX/LCH4) rocket engine

The thermal protection of rocket engines is a crucial aspect of rocket engine design.In this paper,the gas film/regenerative composite cooling of the liquid oxygen/liquid methane(LOX/LCH4)rocket engine thrust chamber was investigated.A gas film/regenerative composite cooling model was developed based on the Grisson gas film cooling efficiency formula and the one-dimensional regenerative cooling model.The accuracy of the model was validated through experiments conducted on a 6 kg/s level gas film/regenerative composite cooling thrust chamber.Additionally,key parameters related to heat transfer performance were calculated.The results demonstrate that the model is sufficiently accurate to be used as a preliminary design tool.The temperature rise error of the coolant,when compared with the experimental results,was found to be less than 10%.Although the pressure drop error is relatively large,the calculated results still provide valuable guidance for heat transfer analysis.In addition,the performance of composite cooling is observed to be superior to regenerative cooling.Increasing the gas film flow rate results in higher cooling efficiency and a lower gas-side wall temperature.Furthermore,the position at which the gas film is introduced greatly impacts the cooling performance.The optimal introduction position for the gas film is determined when the film is introduced from a single row of holes.This optimal introduction position results in a more uniform wall temperature distribution and reduces the peak temperature.Lastly,it is observed that a double row of holes,when compared to a single row of holes,enhances the cooling effect in the superposition area of the gas film and further lowers the gas-side wall temperature.These results provide a basis for the design of gas film/regenerative composite cooling systems.

Improving Film Cooling Performance by Using One-Inlet and Double-Outlet Hole

The film cooling performance of a trunk-branch hole is investigated by numerical simulation in this paper. The geometry of the hole is a novel cooling concept, which controls the vortices-pair existing at the mink hole outlet using the injection of the branch hole. The trunk-branch holes require easily machinable round hole as compared to the shaped holes. The flow cases were considered at the blowing ratios of 0.5, 0.75, 1.0, 1.5 and 2.0. At the low blowing ratio of 0.5, the vortices-pair at the outlet of the trunk hole is reduced and the laterally coverage of the film is improved. At the high blowing ratio of 2.0, the vortices-pair is killed by the vortex which is produced by the injection of the branch hole. The flow rate of the two outlets becomes more significantly different when the blowing ratio increases from 0.75 to 2.0. The discharge coefficients increase 0.15 and the laterally averaged film effectiveness improve 0.2 as compared to the cylindrical holes. The optimal blowing ratios occur at M=1.0 or M= 1.5 according to the various locations downstream of the holes.

Effects of Chemical Reaction Caused by Cooling Stream on Film Cooling Effectiveness

With the increase of inlet temperature of gas turbines, the benefits by using the conventional methods are likely to approach their limits. Therefore, it is essential to study novel film cooling methods for surpassing these current limits. Based on the theory of heat transfer enhancement, a film cooling method with chemical reaction by cool- ing stream is proposed. In order to test the feasibility of the proposed method, numerical simulations have been conducted. The classic flat plate structure with a 30 degree hole is used for the simulation. In the present study, the effects of the parameters in relation to the chemical reaction on film cooling effectiveness, such as chemical heat sink, volume changes, and reaction rate, are investigated numerically. The conventional film cooling is also calculated for the comparison. The results show that film cooling effectiveness is improved obviously due to the chemical reaction, and the reaction heat and reaction rate of cooling stream have an important effect on film ef- fectiveness. However, the effect of volume changes can be ignored.

双叉排气膜孔交互作用对气膜冷却效率影响

采用高精度红外热像仪测量了平板气膜冷却效率,比较了双叉排孔和单排孔气膜冷却效率,分析了孔间的相互作用,以及吹风比(M=0.65、1.00、1.50)和密度比(DR=1.0,1.5)对气膜冷却效率的影响;同时还采用数值计算方法比较了气膜冷却下的流场。结果表明:单排气膜孔冷却效率随着吹风比的增加而降低,但是双叉排气膜孔冷却效率大大提高,且随着吹风比的增加而增加,但是在展向气膜覆盖效果变差;增加密度比可以提高气膜冷却效率,但是双叉排孔和吹风比的影响相对密度比更大;双叉排孔相比于单排孔,冷却气流在孔下游形成了反肾形涡,较好抑制了气膜吹离。

Effects of Blowing Ratio Measured by Liquid Crystal on Heat Transfer Characteristics of Trailing Edge Cutback

This article deals with the effects of a blowing ratio measured with narrowband liquid crystal in transonic experiments on the heat transfer characteristics of trailing edge cutback. The experimental results are compared and contrasted in terms of available data for traditional experiments with thermocouples. It is concluded that the blowing ratio exerts rather significant effects on film cooling effectiveness distribution of the rib center line. As the blowing ratio decreases, similar to the cooling effectiveness distribution curve of the slot center line, that of the rib center line makes a clockwise rotation about the end. When the blowing ratio increases, the regular film cooling effectiveness curve of the surface becomes rather smooth. On the whole measuring surface, the most intensive heat transfer occurs at the extended borderline of the slot and the rib, neither at the rib center line nor at the slot center line. The experimental results of cooling effectiveness measured with thermocouples are lower than those with liquid crystal. In addition, the transient experiments using narrowband liquid crystal can eliminate the higher errors of Nusselt numbers in measurements with thermocouples at the slot outlet.

叶片前缘气膜冷却换热的实验研究

对叶片前缘多排圆柱形孔的气膜冷却换热进行了实验研究。测出了不发生主流侵入腔室的最小平均吹风比、孔排区及其下游的局部换热系数，并研究了主流雷诺数及平均吹风比对局部换热系数比的影响。实验参数范围：主流雷诺数Ｒｅ＝４２０００～１２７０００，平均吹风比Ｍ＝０．８～２．０，测量分８个工况进行。

孔位对涡轮叶片表面气膜冷却换热系数的影响

采用放大的叶片模型,利用大尺寸低速线性叶栅风洞进行实验,测量了涡轮导向叶片表面不同位置单排气膜孔喷射时下游的换热系数,研究了孔排位置、吹风比的影响.风洞实验段由3个叶片组成,中间的叶片为试验叶片,由优质木材制成.试验叶片表面上开有15排气膜孔,吸力面3排,前缘区6排,压力面6排.实验中吹风比的变化范围是0.5～2.5.研究结果表明:由于气膜孔排位置的不同,喷气对换热系数的影响范围不同,换热系数受吹风比影响的变化趋势也有所不同.

涡轮叶片表面气膜冷却的传热实验研究

对压力面和吸力面各有双排气膜孔冷却的涡轮导向叶片表面进行了详细的传热实验研究,在不同吹风比下获得了当地气膜冷却效率和换热系数,结合流场测量结果分析了叶片表面冷却和换热规律。结果表明不同孔排位置叶片表面气膜冷却效率和换热规律有很大不同,孔排位置一定时,冷却效果主要由吹风比决定。结果还表明尽管冷气喷射使型面换热系数随吹风比的增大而显著增大,气膜冷却还是能有效的降低型面的热负荷,其中以中吹风比喷射时冷却效果最为显著。

凹槽状叶顶涡轮叶片传热特性的数值研究

采用计算流体动力学软件ANSYS-CFX数值求解三维Reynolds-Averaged Navier-Stokes(RANS)和标准k-ω紊流模型研究了涡轮叶片凹槽状叶顶的传热特性。数值预测的平顶部叶顶的换热系数分布与实验数据吻合良好,验证了数值方法的可靠性。计算分析了凹槽深度和肩壁厚度对凹槽状叶顶传热特性的影响,还分析了动叶与机匣相对运动下的凹槽状叶顶无气膜冷却和中弧线布置气膜冷却时的流动换热特性。研究结果表明:在肩壁厚度一定时随着凹槽深度的增加叶顶换热系数降低;在1%叶高的叶顶间隙和2%叶高的凹槽深度及4种肩壁条件下1.0mm肩壁厚度时叶顶换热系数最小。相比于动叶与机匣均静止时,动叶和机匣之间的相对运动能够增强动叶顶部的换热效果;动叶与机匣间的相对运动能够增强前缘处气膜冷却效果,总体来说动叶旋转时的离心力和哥氏力对凹槽状叶顶的气膜冷却效果影响有限。

带单排气膜孔的叶片前缘气膜冷却换热实验

针对叶片前缘结构的特点，建立了前缘气膜冷却实验台，实验模型由半圆柱面和两个平板组成，在距离滞止线2倍孔间距位置布置了1排气膜孔。详细地测量了主流湍流度，二次流与主流密度比以及动量比对前缘径向平均换热系数和换热系数比的影响。二次流与主流密度比为1和1．5。动量比变化范围为0．5～4。主流在前缘位置的湍流度分别为0．4％和8％。结果表明，随着动量比的增加，径向平均换热系数增加。无二次流时，湍流度的增加使换热显著增强，有二次流时，湍流度增加使换热增强的幅度较小。密度比对径向平均换热系数的影响非常小。随着孔间距的增加，径向平均换热系数略有减小。径向角对径向平均换热系数的影响较小。在高湍流度下，前缘位置的径向平均换热系数比沿着流动方向是逐渐降低的。在低湍流度下，前缘位置的径向平均换热系数比在x／d=4．5的位置出现了一个峰值。

密度比对涡轮叶片表面气膜冷却换热系数的影响

采用放大的叶片模型,利用大尺寸低速线性叶栅风洞进行试验,测量了涡轮工作叶片表面不同位置处气膜孔下游叶片表面的换热系数,研究了不同吹风比、密度比和雷诺数的影响。风洞试验段由3个叶片组成,其中中间的叶片为试验叶片。试验叶片表面上开有6排气膜孔,其中吸力面1排,前缘区3排,压力面2排。试验结果表明:密度比对叶片表面气膜孔下游换热系数有影响,以往采用空气作为主流及二次流,在低温差下进行试验,所获得的叶片表面气膜孔下游的换热系数在用于涡轮叶片气膜冷却的实际设计时,必须进行修正。

燃气轮机叶片气膜冷却研究进展

综述了近年来燃气轮机涡轮叶片气膜冷却技术的研究成果。介绍了气膜冷却的基本原理,总结了叶片端壁、顶部、前缘及尾缘区域气膜冷却的研究进展和气膜孔流量系数的研究状况,阐述了影响气膜冷却效果的各种因素及气膜冷却对气动损失的影响。最后指出将气膜冷却与其它涡轮叶片冷却技术相结合的复合冷却,应是未来涡轮叶片冷却技术的发展方向。

带肋和气膜孔内冷通道换热机理研究

采用SST k-ω紊流模型,求解三维N-S方程,对带90°肋和气膜孔的矩形通道在入口雷诺数为5×104,气膜孔总出流比为0.22、0.14、0.09和0时进行了换热特性的数值模拟。分析了扰流肋和气膜孔出流使换热增强的机理。结果表明,带肋和气膜孔的通道流场非常复杂,肋和气膜孔出流都会使换热增强。单独带气膜孔的通道,气膜孔出流对上游边界层有抽吸作用,使边界层变薄,导致气膜孔上游区域换热增强;抽吸同时使上游流体发生向下的弯转,冲击气膜孔下游表面,导致气膜孔下游区域换热增强;单独带肋的通道,肋的扰流使换热显著增强;同时带肋和气膜孔的通道,肋是换热强化的主要因素,气膜孔的出流对换热影响较小。

气膜出流冷气侧气膜孔附近壁面换热特性

为对纯气膜出流冷气侧气膜孔局部换热特性进行实验研究。取气膜孔前后3倍气膜孔径范围为研究对象。通过改变来流雷诺数、气膜出流与来流流密比以及通道高度与气膜孔径比(小于1范围内),对气膜孔的“溢流效应”进行了研究。研究发现,气膜孔局部的换热均随来流雷诺数、气膜出流与来流流密比的增加而强化,随通道高度与气膜孔径比的增大而降低;孔后的换热要好于孔前的换热,各种通道高度与气膜孔径比下,孔后1倍孔径区域努塞尔数普遍比孔前提高大约20%以上;在气膜孔前后越靠近孔的地方换热越强。