Engineering topics

McClain, Stephen

Publications and source records attributed to McClain, Stephen.

2 records

DOE OSTI2023

Application of a Distributed Element Roughness Model to Additively Manufactured Internal Cooling Channels

Abstract Design for cooling effectiveness in turbine blades relies on accurate models for dynamic losses and heat transfer of internal cooling passages. Metal additive manufacturing (AM) has expanded the design space for these configurations, but can give rise to large-scale roughness features. The range of roughness length scales in these systems makes morphology resolved computational fluid dynamics (CFD) impractical. However, volumetric roughness models can be leveraged, as they have computational costs orders of magnitude lower. In this work, a discrete element roughness model (DERM), based on the double-averaged Navier–Stokes equations, is presented and applied to additively manufactured rough channels, representative of gas turbine blade cooling passages. Unique to this formulation of DERM is a generalized sheltering-based treatment of drag, a two-layer model for spatially averaged Reynolds stresses, and explicit treatment of dispersion. Six different AM rough surface channel configurations are studied, with roughness trough to peak sizes ranging from 15% to 60% nominal channel passage half-width, and the roughness Reynolds number ranges from Rek = 60 to 300. DERM predictions for spatially and temporally averaged mean flow quantities are compared to previously reported direct numerical simulation results. Good agreement in the mean velocity profiles, stress balances, and drag partitions are observed. While DERM models are typically calibrated to specific deterministic roughness morphologies at comparatively small roughness Reynolds numbers, the present more generalized DERM formulation has wider applicability. Here, it is demonstrated that the model can accommodate random roughness of large scale, typical of AM.

Engineering↗

DOE OSTI2022

Flow in additively manufactured super-rough channels

Metal additive manufacturing has enabled geometrically complex internal cooling channels for turbine and heat exchanger applications, but the process gives rise to large-scale roughness whose size is comparable to the channel height (which is 500 $\mathrm {\mu }$ m). These super-rough channels pose previously unseen challenges for experimental measurements, data interpretation and roughness modelling. First, it is not clear if measurements at a particular streamwise and spanwise location still provide accurate representation of the mean (time- and plane-averaged) flow. Second, we do not know if the logarithmic layer survives. Third, it is unknown how well previously developed rough-wall models work for these large-scale roughnesses. To answer the above practical questions, we conduct direct numerical simulations of flow in additively manufactured super-rough channels. Three rough surfaces are considered, all of which are obtained from computed tomography scans of additively manufactured surfaces. The roughness’ trough to peak sizes are 0.1 $h$ , 0.3 $h$ and 0.8 $h$ , respectively, where $h$ is the intended half-channel height. Each rough surface is placed opposite a smooth wall and the other two rough surfaces, leading to six rough-wall channel configurations. Two Reynolds numbers are considered, namely $Re_\tau =180$ and $Re_\tau =395$ . We show first that measurements at one streamwise and spanwise location are insufficient due to strong mean flow inhomogeneity across the entire channel, second that the logarithmic law of the wall survives despite the mean flow inhomogeneity and third that the established roughness sheltering model remains accurate.

Altland, Samuel↗