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.

Adaptive feedback control of stability in an axial compressor with circumferential inlet distortion

The adaptive feedback control of stability with circumferential inlet distortion has been experimentally investigated in a low-speed,axial compressor.The flat-baffles with different span heights are used to simulate different distorted inflow cases.Compared with auto-correlation and root-mean-square analysis,cross-correlation analysis used to predict early stall warning does not depend on the distortion position.Hence,the cross-correlation coefficient was used to monitor the stable status of the compressor and provide the feedback signal in the active control strategy when suffering from different distortions.Based on the stall margin improvement of tip air injection obtained under different distorted inflow cases and the sensitivity analysis of cross-correlation coefficients to injected momentum ratios,tip air injection was adopted as the actuator for adaptive feedback control.The digital signal processing controller was designed and applied to achieve adaptive feedback control in distorted inflow conditions.The results show that the adaptive feedback control of air injection nearly achieves the same stall margin improvement as steady air injection under different distortion intensities with a reduced injection mass flow.Thus,the proposed adaptive feedback control method is ideal for the engine operation with circumferential distorted inflow,which frequently occurs in flight.

Hybrid Slot-Groove Casing Treatment for Stall Margin Improvement on an Axial Flow Compressor with Circumferential Total Pressure Distortion

The hybrid slot-groove(S-G)casing treatment(CT),which combines the advantages of slot and groove in consideration of stall margin enhancing and efficiency penalty,was experimentally investigated under circumferential distorted inflows.Previous experiments showed that the hybrid S-G CT can extend the stability by 19.79%with uniform inflow condition.To further estimate its stability enhancement ability with distorted inflow,three types of circumferential total pressure distortion inflow that the distorted intensities(DC(60))are equal to 0.90%,4.12%,and 24.75%,are selected to conduct a serial of experiments.Results demonstrated that the stability of the compressor were deteriorated by 7.87%,9.19%and 39.08%respectively under three distorted inflows.It was founded that,under the above-mentioned distorted inflows,the hybrid S-G CT was able to extend the stability by 18.48%,17.81%,and 13.80%,respectively,which proved the strong anti-distortion ability of the hybrid S-G CT.By using the dynamic pressure sensors fixed on the casing wall,the unsteady measurements demonstrated that the stall precursor with uniform and circumferential distorted inflows are always spiky-wave;thus the hybrid S-G CT can play an excellent stability enhancement capability.The analytical results with power spectral density proved that,when at the same flow point,the perturbation,with frequency being around the rotating stall frequency band,was distinctly suppressed by hybrid S-G CT,thus delaying the rotating stall.The stall precursor detected in the casing wall depicted that unlike the short length-scale of stall precursor(5–6 blade passage)under smooth casing;the hybrid S-G CT can create a stall precursor with long length-scale.Under the distortion intensities from 0 to 4.12%,the length scale of the stall precursors occupies approximately 10–12 blade passages.As the distortion intensity further increases to 24.75%,the length scale of stall precursor increases to occupy 16–17 blade passages.This phenomenon can guide the stall warning studies with compressors using CT in the future.

Design Optimization and Analysis of Exit Rotor with Diffuser Passage based on Neural Network Surrogate Model and Entropy Generation Method

In this paper,a diffuser passage compressor design is introduced via optimization to improve the aerodynamic performance of the exit rotor in a multistage axial compressor.An in-house design optimization platform,based on genetic algorithm and back propagation neural network surrogate model,is constructed to perform the optimization.The optimization parameters include diffusion angle of meridian passage,diffusion length of meridian passage,change of blade camber angle and blade number.The impacts of these design parameters on efficiency and stability improvement are analyzed based on the optimization database.Two optimized diffuser passage compressor designs are selected from the optimization solution set by comprehensively considering efficiency and stability of the rotor,and the influencing mechanisms on efficiency and stability are further studied.The simulation results show that the application of diffuser passage compressor design can improve the load coefficient by 12.1%and efficiency by 1.28%at the design mass flow rate condition,and the stall margin can be improved by 12.5%.According to the local entropy generation model analysis,despite the upper and lower endwall loss of the diffuser passage rotor are increased,the profile loss is reduced compared with the original rotor.The efficiency of the diffuser passage rotor can be influenced by both loss and load.At the near stall condition,decreasing flow blockage at blade root region can improve the stall margin of the diffuser passage rotor.

A New Nonspherical Oxidation Model of Metal Particles

This paper analyzes the oxidation law of metal particles and proposes a new oxidation reaction rate model,based on measurements of thermogravimetric-mass spectrometer(TG-MS),X-ray diffractometer(XRD)and scanning electron microscope(SEM).The model is named EBM(egg broken model)with a formula of exponential law.According to the model,the aluminum particles do not react in a spherical shape,but crack and the melted metal inside flows out to form a new nonspherical surface and the reaction rate is still determined by the surface area.The model is verified with heating rates of 5℃/min,10℃/min and 25℃/min,and with particle size of 1–2μm,8–9μm and 20–22μm.Many models are based on spherical hypothesis and the new model gives a different physical illustration to explain oxidation progress of metal particles.The new model gives an exponential law,which fits the experimental data well,and it may be useful to understand oxidation mechanism of metal particles.

A Review on Theoretical and Numerical Research of Axial Compressor Surge

Surge is an unstable operating condition of the aero-engine that can move the engine into a destabilized state and cause devastating damage.One of the most popular topics in the academic and industrial communities is to figure out the mechanism of the surge and withdraw from the surge safely.Based on rig test results and practical data from engine operation,various theories of surge mechanisms have been proposed by researchers,and some classical analytical models have been developed for modelling and prediction.In recent years,with the rapid development of numerical simulation and the improvement of computational capability,computational fluid dynamics(CFD)has been widely applied to the investigation of axial compressor surge events.In this review,the principles and general characteristics of the surge phenomenon are first introduced.Subsequently,the main theoretical models and CFD simulations are presented,and their advantages and disadvantages are discussed.In conclusion,we have proposed potential improvements and future technical routes for the surge phenomenon.The purpose of this paper is to provide a valuable reference for surge studies on axial compressors.

A stall diagnosis method based on entropy feature identification in axial compressors

A stall diagnosis method based on the entropy feature extraction algorithm is developed in axial compressors.The reliability of the proposed method is determined and a parametric sensitivity analysis is experimentally conducted for two different types of compressor stall diagnoses.A collection of time‐resolved pressure sensors is mounted circumferentially and along the chord direction to measure the dynamic pressure on the casing.Results show that the stall and prestall precursor embedded in the dynamic pressures are identified through nonlinear feature perturbation extraction using the entropy feature extraction algorithm.Further analysis demonstrates that the prestall precursor with the peak entropy value is related to the unsteady tip leakage flow for the spike‐type stall diagnosis.The modal wave inception with increasing amplitude is identified by the considerable increase of the entropy value.The flow field in the tip region indicates that the modal wave corresponds to the flow separation in the suction side of the rotor blade.The warning time is 100–300 rotor revolutions for both types of stall diagnoses,which is beneficial for stall control in different axial compressors.Moreover,a parametric study of the embedding dimension m,similar tolerance n,similar radius r,and data length N in the fuzzy entropy method is conducted to determine the optimal parameter setting for stall diagnosis.The stall warning based on the entropy feature extraction algorithm provides a new stall diagnosis approach in the axial compressor with different stall types.This stall warning can also be adopted as an online stability monitoring index when using the concept of active stall control.

Entropy Generation Analysis in a Mixed-Flow Compressor with Casing Treatment

Casing treatments(CT) can effectively extend compressors flow ranges with the expense of efficiency penalty. Compressor efficiency is closely linked to loss. Only revealing the mechanisms of loss generation can design a CT with high aerodynamic performance. In the paper, a highly-loaded mixed-flow compressor with tip clearance of 0.4 mm was numerically studied at a rotational speed of 30,000 r/min to reveal the effects of axial slot casing treatment(ASCT) on the loss mechanisms in the compressor. The results showed that both isentropic efficiency and stall margin were improved significantly by the ASCT. The local entropy generation method was used to analyze the loss mechanisms and to quantify the loss distributions in the blade passage. Based on the axial distributions of entropy generation rate, for both the cases with and without ASCT, the peak entropy generation rate increased in the rotor domain and decreased in the stator domain during throttling the compressor. The peak entropy generation in rotor was mainly caused by the tip leakage flow and flow separations near the rotor leading edge for the mixed-flow compressor no matter which casing was applied. The radial distributions of entropy generation rate showed that the reduction of loss in the rotor domain from 0.4 span to the rotor casing was the major reason for the efficiency improved by ASCT. The addition of ASCT exerted two opposite effects on the losses generated in the compressor. On the one hand, the intensity of tip leakage flow was weakened by the suction effect of slots, which alleviated the mixing effect between the tip leakage flow and main flow, and thus reduced the flow losses;On the other hand, the extra losses upstream the rotor leading edge were produced due to the shear effect and to the heat transfer. The aforementioned shear effect was caused by the different velocity magnitudes and directions, and the heat transfer was caused by temperature gradient between the injected flow and the incoming flow. For case with smooth casing(SC), 61.61% of the overall loss arose from tip leakage flow and casing boundary layer. When the ASCT was applied, that decreased to 55.34%. The loss generated by tip leakage flow and casing boundary layer decreased 20.54% relatively by ASCT.

Application of Fast Wavelet Analysis on Early Stall Warning in Axial Compressors

The timely detection of stall inception is of great significance for safe operation and stability control of axial compressor. In the current study, a fast wavelet tool was selected to predict stall precursor in axial compressors with spike-type and modal-wave stall inception. Dynamic pressure was measured in the casing wall by using a collection of time-resolved pressure transducers with circumferential and chord-wise spatial resolution. Fast wavelet analysis with low frequency reconstruction results demonstrate that the initial inception can be detected 110 rotor revolutions prior to stall for modal-wave stall inception in a 1.5 stage axial compressor. For spike-type stall inception, despite the failure of early stall warning via low frequency reconstruction, an increase amplitude frequency band of 0.2–0.8 blade passing frequency was identified using high frequency reconstruction in an isolated-rotor axial compressor. Fast wavelet method can predict two kinds of stall inceptions simultaneously in advance and realize the early stall warning in axial compressors through a reasonable selection of reconstructed frequency.

Impact of Dual-Volume Helmholtz Dampers on Longitudinal and Azimuthal Thermo-Acoustic Instabilities in an Annular Combustor

Dual-volume Helmholtz dampers with two resonant frequencies are proposed to simultaneously attenuate longitudinal and azimuthal thermo-acoustic instabilities in annular combustors. Thermo-acoustic instabilities in a swirled annular combustor equipped with dual-volume dampers are numerically investigated by the Helmholtz method, combined with a measured flame transfer function and the established damper impedance model. Furthermore, the influences of the damper number and circumferential configurations on oscillation attenuations and mode structures are explored. The established dual-volume damper model is well validated by the impedance tube tests. Numerical results indicate velocity fluctuation levels of the longitudinal and azimuthal modes decline after installing Helmholtz dampers, whereas those of the azimuthal modes further decrease by around 16% after using four retuned dual-volume dampers. The eigenfrequencies of the first longitudinal and azimuthal modes decrease and increase after installing dampers, respectively. After installing dual-volume dampers, the difference between the pressure fluctuation in the plenum and combustion chamber is reduced, and pressure waveforms of the azimuthal modes along the circumferential direction shifts. The pressure distribution of azimuthal modes becomes more uniform after using more dual-volume dampers. The specific absorption frequency band for azimuthal modes introduced by the dual-volume damper may lead to decreased oscillations and mode evolutions. The maximal absorbing ability can be approached by installing dampers with the same angle between adjacent dampers. When dampers are unevenly distributed, the symmetry between two azimuthal modes is broken and standing modes will emerge.

Stall Behaviour in a Mixed-flow Compressor with Axial Slot Casing Treatment

Casing treatment is an effective technique in extending stall margin of axial and centrifugal compressor.However,its impacts on the stall behaviour of mixed-flow compressor are still not completely understood until now.To conquer this issue,unsteady full-annulus simulations were conducted to investigate the stall mechanism of a mixed-flow compressor with and without axial slot casing treatment(ASCT).The circumferential propagating speed of spike inception resolved by the numerical approach is 87.1%of the shaft speed,which is identical to the test data.The numerical results confirmed that the mixed-flow compressor fell into rotating stall via spike-type with and without ASCT.The flow structure of the spike inception was investigated at 50%design rotational speed.Instantaneous static pressure traces extracted upstream of the leading edge had shown a classic spiky wave.Furthermore,it was found that with and without ASCT,the mixed-flow compressor stalled through spike with the characteristic of tip leakage spillage at leading edge and tip leakage backflow from trailing edge,which is different from a fraction of the centrifugal compressor.The resultant phenomenon provides conoborating evidence for that unlike in axial-flow compressor,the addition of ASCT does not change the stall characteristics of the mixed-flow compressor.The flow structure that induced spike inception with ASCT is similar to the case with smooth casing.In the throttling process,tip leakage flow vortex had been involved in the formation of tornado vortices,with one end at the suction side,and the other end at the casing-side.The low-pressure region relevant to the downward spike is caused by leading-edge separation vortex or tornado vortex.The high-pressure region relevant to the upward spike is induced by blockage from the passage vortex.These results not only can provide guidance for the design of casing treatment in mixed-flow compressor,but also can pave the way for the stall waring in the highly-loaded compressors of next-generation aeroengines.

Aerodynamic Performance Improvement of a Highly Loaded Compressor Airfoil with Coanda Jet Flap

Coanda jet flap is an effective flow control technique,which offers pressurized high streamwise velocity to eliminate the boundary layer flow separation and increase the aerodynamic loading of compressor blades.Traditionally,there is only single-jet flap on the blade suction side.A novel Coanda double-jet flap configuration combining the front-jet slot near the blade leading edge and the rear-jet slot near the blade trailing edge is proposed and investigated in this paper.The reference highly loaded compressor profile is the Zierke&Deutsch double-circular-arc airfoil with the diffusion factor of 0.66.Firstly,three types of Coanda jet flap configurations including front-jet,rear-jet and the novel double-jet flaps are designed based on the 2D flow fields in the highly loaded compressor blade passage.The Back Propagation Neural Network(BPNN)combined with the genetic algorithm(GA)is adopted to obtain the optimal geometry for each type of Coanda jet flap configuration.Numerical simulations are then performed to understand the effects of the three optimal Coanda jet flaps on the compressor airfoil performance.Results indicate all the three types of Coanda jet flaps effectively improve the aerodynamic performance of the highly loaded airfoil,and the Coanda double-jet flap behaves best in controlling the boundary layer flow separation.At the inlet flow condition with incidence angle of 5°,the total pressure loss coefficient is reduced by 52.5%and the static pressure rise coefficient is increased by 25.7%with Coanda double-jet flap when the normalized jet mass flow ratio of the front jet and the rear jet is equal to 1.5%and 0.5%,respectively.The impacts of geometric parameters and jet mass flow ratios on the airfoil aerodynamic performance are further analyzed.It is observed that the geometric design parameters of Coanda double-jet flap determine airfoil thickness and jet slot position,which plays the key role in supressing flow separation on the airfoil suction side.Furthermore,there exists an optimal combination of front-jet and rear-jet mass flow ratios to achieve the minimum flow loss at each incidence angle of incoming flow.These results indicate that Coanda double-jet flap combining the adjust of jet mass flow rate varying with the incidence angle of incoming flow would be a promising adaptive flow control technique.

Influence of Hub Contouring on the Performance of a Transonic Axial Compressor Stage with Low Hub-Tip Ratio

The rotor blade height with low hub-tip ratio is relatively longer,and the aerodynamic parameters change drastically from hub to tip.Especially the organization of flow field at hub becomes more difficult.This paper takes a transonic 1.5-stage axial compressor with low hub-tip ratio as the research object.The influence of four types of rotor hub contouring on the performance of transonic rotor and stage is explored through numerical simulation.The three-dimensional numerical simulation results show that different hub contourings have obvious influence on the flow field of transonic compressor rotor and stage,thus affecting the compressor performance.The detailed comparison is conducted at the rotor peak efficiency point for each hub contouring.Compared with the linear hub contouring,the concave hub contouring can improve the flow capacity,improve the rotor working capacity,and increase the flow rate.The flow field near blade root and efficiency of transonic rotor is improved.The convex hub contouring will reduce the mass flow rate,pressure ratio and efficiency of the transonic rotor.Full consideration should be given to the influence of stator flow field by hub contouring.