Int. J. Turbomach. Propuls. Power, Volume 6, Issue 3 (September 2021) – 19 articles

Aeroelastic instabilities such as flutter have a crucial role in limiting the operating range and reliability of turbomachinery. This paper offers an alternative approach to aeroelastic analysis, where the sensitivity of aerodynamic damping with respect to main flow and structural parameters is quantified through a surrogate-model-based investigation. The parameters are chosen based on previous studies and are represented by a uniform distribution within applicable intervals. The surrogate model is an artificial neural network, trained and tested to achieve an error within 1% of the test data. The quantity of interest is aerodynamic damping and the datasets are obtained from a linearised aeroelastic solver. The sensitivity of aerodynamic damping with respect to the input variables is obtained by calculating normalised gradients from the surrogate model at specific operating conditions. The results show a quantitative comparison of sensitivity across the different input parameters. The outcome of the sensitivity analysis is then used to decide the most appropriate action to take in order to induce stability in unstable operating conditions. The work is a preliminary study, carried out on a simplified two dimensional compressor cascade and it is aimed at proving the validity of a data-driven approach in studying the aeroelastic behaviour of turbomachinery. To the best of the authors’ knowledge, this is the first time a data-driven flutter model has been investigated. The initial results are encouraging, indicating that this approach is worth pursuing in the future. The presented framework can be used as a redesign tool to enhance the flutter stability of an existing blade. Full article

The design of organic Rankine cycle (ORC) turbines often requires dealing with transonic flows due to the cycle efficiency requirements and the matching of the temperature profiles with heat sources and sinks, as well as the nature of organic fluids, often featuring high molecular weight. Consequently, the use of convergent–divergent turbine stators has been widely established as a solution in the published literature for use in both axial- and radial-inflow machines. With respect to the latter layout in particular, the available design guidelines are still limited. The present work shows the results of an investigation into a series of ORC radial-inflow convergent–divergent nozzles that differ with respect to the vane count and the designed metal angle of the outlet. These stators were designed by fitting the divergent portion of a sharp-edged minimum-length nozzle, designed by means of the method of characteristics (MoC) adapted to dense gases, into a radial-inflow turbine stator. The geometries were analysed by means of steady-state RANS CFD calculations, and the results were used to assess the influence of the design parameters on the nozzle losses and downstream flow field uniformity, showing that conflicting trends exist between optimum stator efficiency and optimum downstream flow field uniformity. Full article

To meet the challenges of increased thermal loads and performance demands on aero-engine turbine blades, more advanced cooling techniques are required. This study used a modification of the well-known Goldstein equation to predict film effectiveness for an individual film cooling hole and applied the Sellers’ superposition method to apply these films across effusion-cooled configurations. In doing so, it tackles a relatively unchallenged problem of film holes in close spanwise proximity. An experimental set-up utilised infrared cameras to assess the film effectiveness of nine geometries of varying spanwise and streamwise spacings. Higher porosity led to increased thermal protection, and the spanwise spacing had the most profound impact, with film effectiveness approaching 0.9. Additionally, greater uniformity in the spanwise direction was observed. The modified Goldstein-Sellers method showed good agreement with experimental results although lateral mixing was underestimated. This method represents a tool that could be easily implemented in the industry for rapid assessment of novel cooling geometries. Full article

The flow in a transonic turbine stage still poses a high challenge for the correct prediction of turbulence using an eddy viscosity model. Therefore, an unsteady RANS simulation with the k-ω SST model, based on a preceding study of turbulence inlet conditions, was performed to see if this can improve the quality of the flow and turbulence prediction of an experimentally investigated turbine flow. Unsteady Q3D results showed that none of the different turbulence boundary conditions could predict the free-stream turbulence level and the maximum values correctly. Luckily, the influence of the boundary conditions on the velocity field proved to be small. The qualitative prediction of the complex secondary flows is good, but there is lacking agreement in the prediction of turbulence generation and destruction. Full article

The aim of this work is to study the influence of different subgrid-scale (SGS) closure models and inflow turbulence conditions on the boundary layer transition on the suction side of a highly loaded transonic turbine cascade in the presence of high free-stream turbulence using large eddy simulations (LES) of the MUR237 test case. For the numerical simulations, the MUR237 flow case was considered and the incoming free-stream turbulence was reproduced using the synthetic eddy method (SEM). The boundary layer transition on the blade suction side was found to be significantly influenced by the choice of the SGS closure model and the SEM parameters. These two aspects were carefully evaluated in this work. Initially, the influence of three different closure models (Smagorinsky, WALE, and subgrid-scale kinetic energy model) was evaluated. Among them, the WALE SGS closure model performed best compared to the Smagorinsky and KEM models and, for this reason, was used in the following analysis. Finally, different values of the turbulence length scale, eddies density, and inlet turbulence for the SEM were evaluated. As shown by the results, among the different parameters, the choice of the turbulence length scale plays a major role in the transition onset on the blade suction side. Full article

This paper introduces a semi-analytical approach which enables one to deal with distorted inflow in axial fans or compressors. It is inspired by the classical parallel compressor (PC) theory but relies on a local flow-loading coefficient formalism. It is applied to non-uniform flow conditions to study the aerodynamic behavior of a low-speed fan in response to upstream flow distortion. Experimental measurements and 3D RANS simulations are used to evaluate the prediction of fan performance obtained with the local PC method. The comparison proves that, despite its simplicity, the present approach enables to correctly capture first order phenomena, offering interesting perspectives for an early design phase if different fan geometries are to be tested and if the upstream distortion maps are available. Full article

The dimensional analysis and the numerical parametric study of the typical outer air seal from a low-pressure turbine were performed in the framework of the presented paper. The most crucial variables for the flow through the outer air seal were identified and further dimensionless numbers were derived. The dependent quantities resulting from the analysis were: the axial Reynolds number (formulated with the bulk velocity, corresponding to the mass flow through the seal), the outlet swirl ratio (incorporating the exit flow angle, important for mixing) and the windage heating (related to the internal losses). Additionally, the discharge coefficient was cross-checked enabling further comparison with the available literature. The comprehensive numerical parametric study included all important contributors for the flow through the seal with a parameter operating range appropriate for engine outer air seals. Full article

The paper presents a detailed analysis of particle image velocimetry (PIV) measurements performed in a turbine cascade representative of highly accelerated low-pressure turbine (LPT) blades. Two cameras have been simultaneously used to observe a great portion of the suction side boundary layer with the highest possible spatial resolution, thus allowing us to solve the interaction process between impinging upstream wakes and the blade boundary layer. Four unsteady inflow conditions, characterized by different incoming wake reduced frequencies and flow coefficients, have been examined at fixed Reynolds number. The highly resolved flow fields have been processed to explore reduced frequency and flow coefficient effects on the boundary layer unsteady transition process and, consequently, on loss production. For a deep physical insight on the mechanisms responsible for loss generation, proper orthogonal decomposition (POD) has been applied at different phases of the wake passing period. This has provided the dominant structures affecting the cascade aerodynamics during the wake period. Moreover, the examination of POD modes has allowed us to show the effects induced by the parameter variation on the turbulent kinetic energy production and thus to the unsteady loss production mechanisms. Full article

Results on overall pump head and efficiency performance, pressure pulsation and high speed camera visualization of flow patterns behavior are presented for different inlet air-water void fractions at a given rotational speed. With the increase of inlet void fractions and decrease of the flow rates, the size of bubbles increase and tend to agglomerate in specific impeller passage locations along the blade chord. The starting point of pump breakdown is related to a strong inward reverse flow occurring in a specific location near the shroud gap of the impeller and volute tongue region. Using a constant air void fraction value of 2%, pressure pulsation frequency results are analyzed in relation with local flow mixture patterns and flow rate modification. Full article

Variable inlet guide vanes (VIGVs) are most commonly used as the major control unit of integrally geared centrifugal compressors (IGCCs). In order to enhance the efficient operating range of the compressor, the loss mechanisms and utilization limits of state-of-the-art VIGVs need to be better understood. Field measurements in the wake of a typical, commercially used configuration were therefore conducted at the VIGV test facility of the Bundeswehr University Munich. The investigations were carried out at application oriented subsonic flow conditions and stagger angles from 50${}^{\circ }$ to 90${}^{\circ }$ covering the full low-loss operating range, including the limits of efficient operation. For a precise local loss characterization, an inflow correlation was developed and applied to consider total pressure inhomogeneities caused by the radial inflow velocity profile and minor circumferential velocity deviations. Contrary to previous research efforts, not only the profile losses, but also the secondary flow losses induced by the open blade tips and wall-blade interactions were resolved in full detail. For this reason, a more precise and comprehensive loss assessment of realistic VIGV cascades is acquired. Full article

An investigation of hot gas ingestion driven by the disc pumping effect in a chute seal was conducted at the Oxford Rotor Facility. Measurements of mean pressure, unsteady pressure and gas concentration have been logged and analysed under different operating conditions. The sensitivity of mean cavity pressure coefficient, frequency spectra of the unsteady pressures and sealing effectiveness to changing conditions of purge flow, annulus flow, rotor disc speed and seal clearance have been studied. The steady pressures revealed the development of two vortices in the cavity, induced by the sharp change in geometry of the stator wall. The increased shear at the interface between these two vortices strengthened the unsteady activity at this location. The addition of mainstream flow improved the sealing capability of the chute seal under certain operating conditions. The excitation of further frequencies when an axisymmetric annulus flow was introduced suggests a complex interaction between annulus and purge flows. Full article

In stator–rotor interaction studies on axial turbines, the attention is commonly focused on the unsteady rotor aerodynamics resulting from the periodic perturbations induced by the stator flow structures. Conversely, less interest has been historically attracted regarding the influence of the rotor on the flow released by the stator, correlated to propagation of the blade potential field upstream of the rotor leading edge. In this paper, experiments in the research high-pressure turbine of the Laboratory of Fluid-Machines of the Politecnico di Milano, performed by applying a fast-response aerodynamic pressure probe, alongside fully-3D time-accurate CFD simulations of the flow, are combined with the aim of discussing the rotor-to-stator interaction. While rotating, the rotor induces periodic perturbations on the pressure and velocity field in the stator–rotor gap, altering the evolution of the total quantities and the flow rate discharged by each stator channel and eventually triggering energy-separation effects which result in total pressure and total temperature oscillations in the stator-exit flow. Such oscillations were found to rise up to almost ±10% of the stage total temperature drop. Full article

A Large-Eddy Simulation of the tip leakage flow of a single airfoil is carried out. The configuration consists of a non-rotating, isolated airfoil between two horizontal plates with a gap of 10 mm between the tip of the airfoil and the lower plate. The Mach number of the incoming flow is 0.2, and the Reynolds number based on the chord is 9.3 × 10${}^5$. The objective of the present study is to investigate the best way to compute both the aerodynamics and acoustics of the tip leakage flow. In particular, the importance of the inflow conditions on the prediction of the tip leakage vortex and the airfoil loading is underlined. On the other hand, the complex structure of the tip leakage vortex and its convection along the airfoil was recovered due to the use of a mesh adaptation based on the dissipation of the kinetic energy. Finally, the ability of the wall law to model the flow in the tip leakage flow region was proven in terms of wall pressure fluctuations and acoustics in the far-field. Full article

Non-synchronous vibrations arising near the stall boundary of compressors are a recurring and potentially safety-critical problem in modern aero-engines. Recent numerical and experimental investigations have shown that these vibrations are caused by the lock-in of circumferentially convected aerodynamic disturbances and structural vibration modes, and that it is possible to predict unstable vibration modes using coupled linear models. This paper aims to further investigate non-synchronous vibrations by casting a reduced model for NSV in the frequency domain and analysing stability for a range of parameters. It is shown how, and why, under certain conditions linear models are able to capture a phenomenon, which has traditionally been associated with aerodynamic non-linearities. The formulation clearly highlights the differences between convective non-synchronous vibrations and flutter and identifies the modifications necessary to make quantitative predictions. Full article

Unsteady pressure fluctuations measured by fast-response pressure transducers mounted in a low-pressure turbine cascade are compared to unsteady simulation results. Three differing simulation approaches are considered, one time-integration method and two harmonic balance methods either resolving or averaging the time-dependent components within the turbulence model. The observations are used to evaluate the capability of the harmonic balance solver to predict the transient pressure fluctuations acting on the investigated stator surface. Wakes of an upstream rotor are generated by moving cylindrical bars at a prescribed rotational speed that refers to a frequency of $f\sim 500$ Hz. The excitation at the rear part of the suction side is essentially driven by the presence of a separation bubble and is therefore highly dependent on the unsteady behavior of turbulence. In order to increase the stability of the investigated harmonic balance solver, a developed Lanczos-type filter method is applied if the turbulence model is considered in an unsteady fashion. Full article

A preliminary analysis of turbine design, fit for pulsed flow, is proposed in this paper. It focuses on an academic 2D configuration using inviscid flows, since pressure loads due to wave propagation are several orders of magnitude higher than friction and viscous effects do not significantly impinge on the inviscid part, as previously shown by Hermet, 2021. As such, a large parametric study was carried out using the design of experiments methodology. A performance indicator adapted to unsteady environment is carefully defined before detailing the factors chosen for the design of experiments. Since the number of factors is substantial, a screening design to identify the factors influence on the output is first established. The non-influential factors are then omitted in a more quantitative study of the output law. The surface response calculation allows determining the factor level favouring the best output. Consequently, the main trends in the turbine design driven by a pulsed flow can be stated. Full article

Radial turbines used in automotive fuel cell turbochargers operate with humid air. The gas expansion in the turbine causes droplets to form, which then grow through condensation. The associated release of latent heat and decrease in the gaseous mass flow strongly influence the thermodynamics of the turbine. This study aims to investigate these phenomena. For this purpose, the classical nucleation theory and Young’s growth law are integrated into a Euler–Lagrange approach. The main advantages of this approach are the calculation of individual droplet trajectories and a full resolution of the droplet spectrum. The results indicate an onset of nucleation at the blade tip and in the tip gap, followed by nucleation over the entire blade span, depending on the humidity at the turbine inlet. With a saturated turbine inflow, condensation causes the outlet temperature to rise to almost the same level as at the inlet. In addition, condensation losses reduce the efficiency and the latent heat released by condensation leads to significant thermal throttling. Full article

A feasibility study of velocity field measurements using the Particle Image Velocimetry (PIV) method in an axial air turbine model is presented. The wakes past the blades of the rotor wheel were observed using the PIV technique. Data acquisition was synchronized with the shaft rotation; thus, the wakes were phase averaged for statistical analysis. The interaction of the rotor blade wakes with the stator ones was investigated by changing the stator wheel’s angle. The measurement planes were located just behind the rotor blades, covering approximately 3 cm × 3 cm in axial × tangential directions. The spatial correlation function suggests that the resolution used is sufficient for the large-scale flow-patterns only, but not for the small ones. The scales of fluctuations correspond to the shear layer thickness at the mid-span plane but, close to the end-wall, they contain larger structures caused by the secondary flows. The length-scales of the fluctuations under off-design conditions display a dependence on the area of the stator and rotor wakes cross-sections, which, in turn, depend on their angle. The obtained experimental data are to be used for the validation of mathematical simulation results in the future. Full article

This paper experimentally investigates a highly-loaded 1.5-stage transonic axial compressor, which comprises a variable inlet guide vane, a BLISK rotor, and a variable stator in tandem arrangement. A detailed comparison between the newly designed compressor stage and a reference stage with a conventional stator design was conducted by using extensive instrumentation. Thus, steady and unsteady phenomena—focusing on the aerodynamic and aeroelastic behavior—were analyzed. Due to the new stator vane design, a higher aerodynamic stator vane loading was pursued, while the vane count was reduced. This, in turn, allowed a rotor design with an increased work coefficient. This experimental study revealed several effects of the optimized compressor stage in terms of both performance and the corresponding aerodynamics, as well as the aeroelastic behavior. Full article