Results for “Flow rate ratio” — Page 12

NASA NTRSDate not supplied

Wind Tunnel Testing of AFC over a Deflected Aileron on the High-Lift Common Research Model

Active flow control (AFC) using discrete fluidic actuators distributed along the span, just upstream of the deflected aileron of the 10% scale high-lift version of the Common Research Model (CRM-HL), was evaluated during a wind tunnel test in the NASA Langley 14- by 22-Foot Subsonic Tunnel. For this set of experiments, a new outboard section was fabricated incorporating a deflectable aileron. Aileron deflection angles of 0, 7.5, 16, and 25 were investigated. This experimental investigation is in response to a recent study by Boeing potential to use AFC with a drooped aileron during takeoff to improve lift-to-drag ratio (L/D) by as much as 5%, depending on AFC mass flow rate. AFC is used at deflection angles above the nominal deflection of 7.5 to control the resulting flow separation that occurs and potentially improve L/D. Improvements in aircraft low-speed L/D can affect vehicle range and/or payload. Tuft flow visualization data, steady and unsteady surface pressure data, and force and moment data are used to compare the flowfields with and without AFC. Parameters varied include actuator momentum coefficient and aileron deflection angle. The surface pressure and tuft flow visualization results indicate that without AFC, the flow over a majority of the aileron upper surface is separated for aileron deflection angles larger than 7.5. When AFC is applied, the flow is reattached to the aileron. Force and moment results show that a local increase in lift leads to an increase in L/D of at least 3.5% using mass flow rates thought to be available from air sources onboard a commercial transport.

AFC↗

NASA NTRS1985

Studies on effects of boundary conditions in confined turbulent flow predictions

The differences in k epsilon model predictions of plane and axisymmetric expansion flows is investigated. The prediction of the coaxial jet for different velocity ratios of the annular to central jet is presented. The effects of inlet kinetic energy and the energy dissipation rate profiles are investigated for swirling and nonswirling flows. The effects of expansion ration and Reynolds number on the reattachment length are also presented. The results show that the inlet k and epsilon profiles have the most significant effect on the reattachment length and flow redevelopment for the case of coaxial jet of high velocity ratio. A comparison of k epsilon model predictions for the pipe expansion flow by the PHOENICS and TEACH codes reveals some discrepancies in the predicted results. TEACH prediction seems to produce unrealistic kinetic energy profiles in some regions of the flow. PHOENICS code produces a long tail in the recirculation region under certain conditions.

Nallasamy, M.↗

NASA NTRS2000

Ice-age Ice-sheet Rheology: Constraints from the Last Glacial Maximum Form of the Laurentide Ice Sheet

State-ot-the-art thermomechanical models of the modern Greenland ice and the ancient Laurenticle ice sheet that covered Canada at the Last Glacial Maximum (LGM) are not able to explain simultaneously the observed forms of these cryospheric structures when the same, anisotropy-enhanced, version of the conventional Glen flow law is employed to describe their rheology. The LGM Laurenticle ice sheet. predicted to develop in response to orbital climate forcing, is such that the ratio of its thickness to its horizontal extent is extremely large compared to the aspect ratio inferred on the basis of surface-geomorphological and solid-earth-geophysical constraints. We show that if the Glen flow law representation of the rheology is replaced with a new rheology based upon very high quality laboratory measurements of the stress-strain-rate relation, then the aspect ratios of both the modern Greenland ice sheet and the Laurenticle ice sheet, that existed at the LGM, are simultaneously explained with little or no retuning of the flow law.

Peltier, W. Richard↗

NASA NTRS1990

Arcjet Nozzle Area Ratio Effects

An experimental investigation was conducted to determine the effect of nozzle area ratio on the operating characteristics and performance of a low power dc arcjet thruster. Conical thoriated tungsten nozzle inserts were tested in a modular laboratory arcjet thruster run on hydrogen/nitrogen mixtures simulating the decomposition products of hydrazine. The converging and diverging sides of the inserts had half angles of 30 and 20 degrees, respectively, similar to a flight type unit currently under development. The length of the diverging side was varied to change the area ratio. The nozzle inserts were run over a wide range of specific power. Current, voltage, mass flow rate, and thrust were monitored to provide accurate comparisons between tests. While small differences in performance were observed between the two nozzle inserts, it was determined that for each nozzle insert, arcjet performance improved with increasing nozzle area ratio to the highest area ratio tested and that the losses become very pronounced for area ratios below 50. These trends are somewhat different than those obtained in previous experimental and analytical studies of low Re number nozzles. It appears that arcjet performance can be enhanced via area ratio optimization.

Curran, Francis M.↗

NASA NTRS1990

Arcjet nozzle area ratio effects

An experimental investigation was conducted to determine the effect of nozzle area ratio on the operating characteristics and performance of a low power dc arcjet thruster. Conical thoriated tungsten nozzle inserts were tested in a modular laboratory arcjet thruster run on hydrogen/nitrogen mixtures simulating the decomposition products of hydrazine. The converging and diverging sides of the inserts had half angles of 30 and 20 degrees, respectively, similar to a flight type unit currently under development. The length of the diverging side was varied to change the area ratio. The nozzle inserts were run over a wide range of specific power. Current, voltage, mass flow rate, and thrust were monitored to provide accurate comparisons between tests. While small differences in performance were observed between the two nozzle inserts, it was determined that for each nozzle insert, arcjet performance improved with increasing nozzle area ratio to the highest area ratio tested and that the losses become very pronounced for area ratios below 50. These trends are somewhat different than those obtained in previous experimental and analytical studies of low Re number nozzles. It appears that arcjet performance can be enhanced via area ratio optimization.

Curran, Francis M.↗

NASA NTRSDate not supplied

Simulations of the Modular Axisymmetric Scramjet Test Rig Under Reacting Flow Conditions

Simulations of the Air Force Research Laboratory (AFRL) Modular Axisymmetric Scramjet Test Rig (MASTeR) are presented. MASTeR is a parametric test article capable of investigating various scramjet cavity flameholder designs and fueling strategies with the goal to characterize and optimize flameholding capability. In the current work, three cavity aspect ratios, three depths, and two fueling strategies (upstream and in-cavity) with ethylene at a nominal facility pressure and temperature conditions are evaluated. The simulations are performed for mixing-only and reacting flows, and the resulting flow characteristics are compared. For each configuration and fueling strategy, cavity residence time, entrainment rate, and fuel-air equivalence ratio are computed. The MASTeR geometry is defined in the Engineering Sketch Pad (ESP) and the simulations use a sketch-to-solution (S2S) automated unstructured grid adaptation tool in VULCAN-CFD. This tool automatically generates a simulation grid from the ESP geometry and systematically adapts it to the numerical solution based on the Hessian error estimate of a specified flow field parameter. Reynolds averaged simulations (RAS) are used with typical two-equation linear eddy viscosity and diffusivity model. The resulting database can be compared with the experimental data as those becomes available and explored to develop models for cavity performance for scramjet propulsion design applications.

hypersonics↗

NASA NTRS2007

Experimental Results of Performance Tests on a Four-Port Wave Rotor

A series of tests has been performed on a four-port wave rotor suitable for use as a topping stage on a gas turbine engine, to measure the overall pressure ratio obtainable as a function of temperature ratio, inlet mass flow, loop flow ratio, and rotor speed. The wave rotor employed an open high pressure loop that is the high pressure inlet flow was not the air exhausted from the high pressure outlet, but was obtained from a separate heated source, although the mass flow rates of the two flows were balanced. This permitted the choice of a range of loop-flow ratios (i.e., ratio of high pressure flow to low pressure flow), as well as the possibility of examining the effect of mass flow imbalance. Imbalance could occur as a result of leakage or deliberate bleeding for cooling air. Measurements of the pressure drop in the high pressure loop were also obtained. A pressure ratio of 1.17 was obtained at a temperature ratio of 2.0, with an inlet mass flow of 0.6 lb/s. Earlier tests had given a pressure ratio of less than 1.12. The improvement was due to improved sealing between the high pressure and low pressure loops, and a modification to the movable end-wall which is provided to allow for rotor expansion.

Wilson, John↗

NASA NTRS1995

Velocity Fields of Axisymmetric Hydrogen-Air Counterflow Diffusion Flames from LDV, PIV, and Numerical Computation

Laminar fuel-air counterflow diffusion flames (CFDFs) were studied using axisymmetric convergent-nozzle and straight-tube opposed jet burners (OJBs). The subject diagnostics were used to probe a systematic set of H2/N2-air CFDFs over wide ranges of fuel input (22 to 100% Ha), and input axial strain rate (130 to 1700 Us) just upstream of the airside edge, for both plug-flow and parabolic input velocity profiles. Laser Doppler Velocimetry (LDV) was applied along the centerline of seeded air flows from a convergent nozzle OJB (7.2 mm i.d.), and Particle Imaging Velocimetry (PIV) was applied on the entire airside of both nozzle and tube OJBs (7 and 5 mm i.d.) to characterize global velocity structure. Data are compared to numerical results from a one-dimensional (1-D) CFDF code based on a stream function solution for a potential flow input boundary condition. Axial strain rate inputs at the airside edge of nozzle-OJB flows, using LDV and PIV, were consistent with 1-D impingement theory, and supported earlier diagnostic studies. The LDV results also characterized a heat-release hump. Radial strain rates in the flame substantially exceeded 1-D numerical predictions. Whereas the 1-D model closely predicted the max I min axial velocity ratio in the hot layer, it overpredicted its thickness. The results also support previously measured effects of plug-flow and parabolic input strain rates on CFDF extinction limits. Finally, the submillimeter-scale LDV and PIV diagnostics were tested under severe conditions, which reinforced their use with subcentimeter OJB tools to assess effects of aerodynamic strain, and fueVair composition, on laminar CFDF properties, including extinction.

Pellett, Gerald L.↗

NASA NTRS2010

Fuel-Cell Water Separator

The main product of a typical fuel cell is water, and many fuel-cell configurations use the flow of excess gases (i.e., gases not consumed by the reaction) to drive the resultant water out of the cell. This two-phase mixture then exits through an exhaust port where the two fluids must again be separated to prevent the fuel cell from flooding and to facilitate the reutilization of both fluids. The Glenn Research Center (GRC) has designed, built, and tested an innovative fuel-cell water separator that not only removes liquid water from a fuel cell s exhaust ports, but does so with no moving parts or other power-consuming components. Instead it employs the potential and kinetic energies already present in the moving exhaust flow. In addition, the geometry of the separator is explicitly intended to be integrated into a fuel-cell stack, providing a direct mate with the fuel cell s existing flow ports. The separator is also fully scalable, allowing it to accommodate a wide range of water removal requirements. Multiple separators can simply be "stacked" in series or parallel to adapt to the water production/removal rate. GRC s separator accomplishes the task of water removal by coupling a high aspect- ratio flow chamber with a highly hydrophilic, polyethersulfone membrane. The hydrophilic membrane readily absorbs and transports the liquid water away from the mixture while simultaneously resisting gas penetration. The expansive flow path maximizes the interaction of the water particles with the membrane while minimizing the overall gas flow restriction. In essence, each fluid takes its corresponding path of least resistance, and the two fluids are effectively separated. The GRC fuel-cell water separator has a broad range of applications, including commercial hydrogen-air fuel cells currently being considered for power generation in automobiles.

Burke, Kenneth Alan↗

NASA NTRS2007

Experimental Study of an Axisymmetric Dual Throat Fluidic Thrust Vectoring Nozzle for Supersonic Aircraft Application

An axisymmetric version of the Dual Throat Nozzle concept with a variable expansion ratio has been studied to determine the impacts on thrust vectoring and nozzle performance. The nozzle design, applicable to a supersonic aircraft, was guided using the unsteady Reynolds-averaged Navier-Stokes computational fluid dynamics code, PAB3D. The axisymmetric Dual Throat Nozzle concept was tested statically in the Jet Exit Test Facility at the NASA Langley Research Center. The nozzle geometric design variables included circumferential span of injection, cavity length, cavity convergence angle, and nozzle expansion ratio for conditions corresponding to take-off and landing, mid climb and cruise. Internal nozzle performance and thrust vectoring performance was determined for nozzle pressure ratios up to 10 with secondary injection rates up to 10 percent of the primary flow rate. The 60 degree span of injection generally performed better than the 90 degree span of injection using an equivalent injection area and number of holes, in agreement with computational results. For injection rates less than 7 percent, thrust vector angle for the 60 degree span of injection was 1.5 to 2 degrees higher than the 90 degree span of injection. Decreasing cavity length improved thrust ratio and discharge coefficient, but decreased thrust vector angle and thrust vectoring efficiency. Increasing cavity convergence angle from 20 to 30 degrees increased thrust vector angle by 1 degree over the range of injection rates tested, but adversely affected system thrust ratio and discharge coefficient. The dual throat nozzle concept generated the best thrust vectoring performance with an expansion ratio of 1.0 (a cavity in between two equal minimum areas). The variable expansion ratio geometry did not provide the expected improvements in discharge coefficient and system thrust ratio throughout the flight envelope of typical a supersonic aircraft. At mid-climb and cruise conditions, the variable geometry design compromised thrust vector angle achieved, but some thrust vector control would be available, potentially for aircraft trim. The fixed area, expansion ratio of 1.0, Dual Throat Nozzle provided the best overall compromise for thrust vectoring and nozzle internal performance over the range of NPR tested compared to the variable geometry Dual Throat Nozzle.

Flamm, Jeffrey D.↗

NASA NTRS1996

Spectroscopic Diagnostics and an Arc Jet Heated Air Plasma

Spectral radiation measurements were made in the range of 200 to 900 nm across a section of the plenum of an arc jet wind tunnel using a series of optical fibers. The spectra contained line radiation from Oxygen and Nitrogen atoms and molecular radiation from N2(+), N2, and NO. Abel inversion technique is used to obtain radial distribution of the spectra. The analysis yielded radial profiles of the electronic excitation, vibrational and rotational temperatures of the flow field. Spectral fitting yielded branching ratios for different vibrational and rotational bands. Relatively mild flow conditions, i.e. enthalpy and mass flow rate, were used for prolonged measurements of up to and over two hours to establish the best experimental methods of temperature determinations. Signal to noise was improved by at least an order of magnitude enabling the molecular vibrational band heads of N2(+) (first negative system), N2 (second positive system), and NO (beta, gamma, delta, and epsilon systems) to be resolved in the lower ultraviolet wavelength regions. The increased signal to noise ratio also enabled partial resolution of the rotational lines of N2(+) and N2 in certain regions of minimal overlap. Comparison of the spectra with theoretical models such as the NEQAIR2 code are presented and show potential for fitting the spectra when reliable calibration is performed for the complete wavelength range.

Mack, Larry Howard, Jr.↗

NASA NTRS1993

Optical information in landing scenes

During landing, the visual scene contains optical information about speed, altitude, glide slope, and track that is useful for the maintenance of spatial orientation and awareness. This information, embedded in the structure and transformations of the optical patterns, may be globally, regionally, or locally available. Global changes occur everywhere in the visual field during landing and include such information as flow rate acceleration due to changing speed and/or altitude. Regional changes occur within a more restricted area and include such information as horizon line motion due to aircraft pitching and rolling. Locally available changes are the most restricted and include such information as changes in runway form ratios due to changing glide slopes. Thus, within partially or fully synthetic displays, or within sensor-driven displays, preservation of flow rate and horizon motion information requires a minimum of knowledge about the details of the airport layout, while runway outlines do require much more knowledge of the layout. All may be important, however, and these, as well as other sources of optical information, can provide a pilot with his most natural framework for maintaining orientation.

Johnson, Walter W.↗

NASA NTRS1974

Effect of wall to total temperature ratio variation on heat transfer to the leeside of a space shuttle configuration at M equals 10.3

An experimental study has been conducted of the influence of wall to total temperature ratio on the heat transfer to the leeside of a 040A space shuttle configuration. The heat transfer tests were made at a Mach number of 10 and a Reynolds number of one million per foot for angles of attack from 0 deg to 30 deg. Range of wall to total temperature ratio was from 0.16 to 0.43. Where the heat transfer was relatively high and the laminar boundary layer attached, the local heat transfer decreased by about 20 percent as the wall to total temperature ratio was increased from the minimum to the maximum test value. On regions of separated flow and vortex reattachment, very low heating rates were measured at some conditions and indicate significant changes are occurring in the leeside flow field. No single trend of heat transfer variation with wall to total temperature ratio could be observed.

Dunavant, J. C.↗

NASA NTRS1975

Renal effects of continuous negative pressure breathing

Continuous negative pressure breathing (CNPB) was utilized to simulate the thoracic vascular distension of zero G in 11 anesthetized rats. The animals underwent renal clearance and micropuncture renal nephron studies before, during, and after CNPB. Four rats were pretreated with a high salt diet and I-M desoxycorticosterone (DOCA) in excess. None of these rats diuresed with CNPB. In contrast, five of the seven remaining rats increased the fraction of the filtered sodium excreted and their urinary flow rate. Potassium excretion increased. End proximal tubular fluid specimen's TF/P inulin ratios were unchanged. Whole kidney and single nephron glomerular filtration rates fell 10%. CNPB, a mechanism for atrial distension, appears to cause in the rat a decrease in distal tubular sodium and water reabsorption. Exogenous mineral-corticoid prevents the diuresis, saluresis, and kaluresis. The adequacy of other nonatrial volume control mechanisms in regulating renal salt and water conservation in opposition to the studied atrial-renal (Henry-Gauer) reflex of thoracic vascular distension is confirmed.

Kinney, M. J.↗

NASA NTRS1984

Real jet effects on dual jets in a crossflow

A 6-ft by 6-ft wind tunnel section was modification to accommodate the 7-ft wide NASA dual-jet flate model in an effort to determine the effects of nonuniform and/or noncircular jet exhaust profiles on the pressure field induced on a nearby surface. Tests completed yield surface pressure measurements for a 90 deg circular injector producing exit profiles representative of turbofan nozzles (such as the TF-34 nozzle). The measurements were obtained for both tandem and side-by-side jet configurations, jet spacing of S/D =2, and velocity ratios of R=2.2 and 4.0. Control tests at the same mass flow rate but with uniform exit velocity profiles were also conducted, for comparison purposes. Plots for 90 deg injection and R=2.2 show that the effects of exit velocity profile nonuniformity are quite significant.

Schetz, J. A.↗

NASA NTRS2004

NASA Glenn's Single-Stage Axial Compressor Facility Upgraded

NASA Glenn Research Center's Single-Stage Axial Compressor Facility was upgraded in fiscal year 2003 to expand and improve its research capabilities for testing high-speed fans and compressors. The old 3000-hp drive motor and gearbox were removed and replaced with a refurbished 7000-hp drive motor and gearbox, with a maximum output speed of 21,240 rpm. The higher horsepower rating permits testing of fans and compressors with higher pressure ratio or higher flow. A new inline torquemeter was installed to provide an alternate measurement of fan and compressor efficiency, along with the standard pressure and temperature measurements. A refurbished compressor bearing housing was also installed with bidirectional rotation capability, so that a variety of existing hardware could be tested. Four new lubrication modules with backup capability were installed for the motor, gearbox, torquemeter, and compressor bearing housing, so that in case the primary pump fails, the backup will prevent damage to the rotating hardware. The combustion air supply line for the facility inlet air system was activated to provide dry air for repeatable inlet conditions. New flow conditioning hardware was installed in the facility inlet plenum tank, which greatly reduced the inlet turbulence. The new inlet can also be easily modified to accommodate 20- or 22-in.-diameter fans and compressors, so a variety of existing hardware from other facilities (such as Glenn's 9- by 15-Foot Low-Speed Wind Tunnel) can be tested in the Single-Stage Axial Compressor Facility. An exhaust line was also installed to provide bleed capability to remove the inlet boundary layer. To improve the operation and control of the facility, a new programmable logic controller (PLC) was installed to upgrade from hardwired relay logic to software logic. The PLC also enabled the usage of human-machine interface software to allow for easier operation of the facility and easier reconfiguration of the facility controls when necessary. Finally, a new health-monitoring system was installed to measure shaft speed, shaft movement, and machine vibration on all of the rotating equipment. The system also provides automatic alarms and shutdown of the equipment when required. An integrated systems test for checkout of the facility was completed on June 17, 2003. Research testing resumed on June 30 with data obtained in support of the Ultra-Efficient Engine Technology Project's Compressor Casing Treatment Project.

Brokopp, Richard A.↗

NASA NTRS2014

High Efficiency Centrifugal Compressor for Rotorcraft Applications

The report "High Efficiency Centrifugal Compressor for Rotorcraft Applications" documents the work conducted at UTRC under the NRA Contract NNC08CB03C, with cost share 2/3 NASA, and 1/3 UTRC, that has been extended to 4.5 years. The purpose of this effort was to identify key technical barriers to advancing the state-of-the-art of small centrifugal compressor stages; to delineate the measurements required to provide insight into the flow physics of the technical barriers; to design, fabricate, install, and test a state-of-the-art research compressor that is representative of the rear stage of an axial-centrifugal aero-engine; and to acquire detailed aerodynamic performance and research quality data to clarify flow physics and to establish detailed data sets for future application. The design activity centered on meeting the goal set outlined in the NASA solicitation-the design target was to increase efficiency at higher work factor, while also reducing the maximum diameter of the stage. To fit within the existing Small Engine Components Test Facility at NASA Glenn Research Center (GRC) and to facilitate component re-use, certain key design parameters were fixed by UTRC, including impeller tip diameter, impeller rotational speed, and impeller inlet hub and shroud radii. This report describes the design effort of the High Efficiency Centrifugal Compressor stage (HECC) and delineation of measurements, fabrication of the compressor, and the initial tests that were performed. A new High-Efficiency Centrifugal Compressor stage with a very challenging reduction in radius ratio was successfully designed, fabricated and installed at GRC. The testing was successful, with no mechanical problems and the running clearances were achieved without impeller rubs. Overall, measured pressure ratio of 4.68, work factor of 0.81, and at design exit corrected flow rate of 3 lbm/s met the target requirements. Polytropic efficiency of 85.5 percent and stall margin of 7.5 percent were measured at design flow rate and speed. The measured efficiency and stall margin were lower than pre-test CFD predictions by 2.4 percentage points (pt) and 4.5 pt, respectively. Initial impressions from the experimental data indicated that the loss in the efficiency and stall margin can be attributed to a design shortfall in the impeller. However, detailed investigation of experimental data and post-test CFD simulations of higher fidelity than pre-test CFD, and in particular the unsteady CFD simulations and the assessment with a wider range of turbulence models, have indicated that the loss in efficiency is most likely due to the impact of unfavorable unsteady impeller/diffuser interactions induced by diffuser vanes, an impeller/diffuser corrected flow-rate mismatch (and associated incidence levels), and, potentially, flow separation in the radial-to-axial bend. An experimental program with a vaneless diffuser is recommended to evaluate this observation. A subsequent redesign of the diffuser (and the radial-to-axial bend) is also recommended. The diffuser needs to be redesigned to eliminate the mismatching of the impeller and the diffuser, targeting a slightly higher flow capacity. Furthermore, diffuser vanes need to be adjusted to align the incidence angles, to optimize the splitter vane location (both radially and circumferentially), and to minimize the unsteady interactions with the impeller. The radial-to-axial bend needs to be redesigned to eliminate, or at least minimize, the flow separation at the inner wall, and its impact on the flow in the diffuser upstream. Lessons were also learned in terms of CFD methodology and the importance of unsteady CFD simulations for centrifugal compressors was highlighted. Inconsistencies in the implementation of a widely used two-equation turbulence model were identified and corrections are recommended. It was also observed that unsteady simulations for centrifugal compressors require significantly longer integration times than what is current practice in industry.

Gorazd Medic↗

NASA NTRS2014

High Efficiency Centrifugal Compressor for Rotorcraft Applications

The report "High Efficiency Centrifugal Compressor for Rotorcraft Applications" documents the work conducted at UTRC under the NRA Contract NNC08CB03C, with cost share 2/3 NASA, and 1/3 UTRC, that has been extended to 4.5 years. The purpose of this effort was to identify key technical barriers to advancing the state-of-the-art of small centrifugal compressor stages; to delineate the measurements required to provide insight into the flow physics of the technical barriers; to design, fabricate, install, and test a state-of-the-art research compressor that is representative of the rear stage of an axial-centrifugal aero-engine; and to acquire detailed aerodynamic performance and research quality data to clarify flow physics and to establish detailed data sets for future application. The design activity centered on meeting the goal set outlined in the NASA solicitation-the design target was to increase efficiency at higher work factor, while also reducing the maximum diameter of the stage. To fit within the existing Small Engine Components Test Facility at NASA Glenn Research Center (GRC) and to facilitate component re-use, certain key design parameters were fixed by UTRC, including impeller tip diameter, impeller rotational speed, and impeller inlet hub and shroud radii. This report describes the design effort of the High Efficiency Centrifugal Compressor stage (HECC) and delineation of measurements, fabrication of the compressor, and the initial tests that were performed. A new High-Efficiency Centrifugal Compressor stage with a very challenging reduction in radius ratio was successfully designed, fabricated and installed at GRC. The testing was successful, with no mechanical problems and the running clearances were achieved without impeller rubs. Overall, measured pressure ratio of 4.68, work factor of 0.81, and at design exit corrected flow rate of 3 lbm/s met the target requirements. Polytropic efficiency of 85.5 percent and stall margin of 7.5 percent were measured at design flow rate and speed. The measured efficiency and stall margin were lower than pre-test CFD predictions by 2.4 percentage points (pt) and 4.5 pt, respectively. Initial impressions from the experimental data indicated that the loss in the efficiency and stall margin can be attributed to a design shortfall in the impeller. However, detailed investigation of experimental data and post-test CFD simulations of higher fidelity than pre-test CFD, and in particular the unsteady CFD simulations and the assessment with a wider range of turbulence models, have indicated that the loss in efficiency is most likely due to the impact of unfavorable unsteady impeller/diffuser interactions induced by diffuser vanes, an impeller/diffuser corrected flow-rate mismatch (and associated incidence levels), and, potentially, flow separation in the radial-to-axial bend. An experimental program with a vaneless diffuser is recommended to evaluate this observation. A subsequent redesign of the diffuser (and the radial-to-axial bend) is also recommended. The diffuser needs to be redesigned to eliminate the mismatching of the impeller and the diffuser, targeting a slightly higher flow capacity. Furthermore, diffuser vanes need to be adjusted to align the incidence angles, to optimize the splitter vane location (both radially and circumferentially), and to minimize the unsteady interactions with the impeller. The radial-to-axial bend needs to be redesigned to eliminate, or at least minimize, the flow separation at the inner wall, and its impact on the flow in the diffuser upstream. Lessons were also learned in terms of CFD methodology and the importance of unsteady CFD simulations for centrifugal compressors was highlighted. Inconsistencies in the implementation of a widely used two-equation turbulence model were identified and corrections are recommended. It was also observed that unsteady simulations for centrifugal compressors require significantly longer integration times than what is current practice in industry.

Gorazd Medic↗