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DOE OSTI2023

Turbine airfoil with leading edge cooling passage(s) coupled via plenum to film cooling holes, and related method

A turbine airfoil includes a body including a wall defining pressure and suction sides, and a leading edge extending between the pressure and suction sides. A cooling circuit inside the wall of the body includes at least one of: a) a suction side to pressure side cooling sub-circuit including a first cooling passage(s) extending from the suction side to the pressure side around the leading edge to a first plenum, and a plurality of first film cooling holes communicating with the first plenum and extending through the wall on the pressure side; and b) a pressure side to suction side cooling sub-circuit including second cooling passage(s) extending from the pressure side to the suction side around the leading edge to a second plenum, and a plurality of second film cooling holes communicating with the second plenum and extending through the wall on the suction side.

Lacy, Benjamin Paul↗

NASA NTRS2014

Long Hole Film Cooling Dataset for CFD Development - Flow and Film Effectiveness

An experiment investigating flow and heat transfer of long (length to diameter ratio of 18) cylindrical film cooling holes has been completed. In this paper, the thermal field in the flow and on the surface of the film cooled flat plate is presented for nominal freestream turbulence intensities of 1.5 and 8 percent. The holes are inclined at 30 deg above the downstream direction, injecting chilled air of density ratio 1.0 onto the surface of a flat plate. The diameter of the hole is 0.75 in. (approx. 0.02 m) with center to center spacing (pitch) of 3 hole diameters. Coolant was injected into the mainstream flow at nominal blowing ratios of 0.5, 1.0, 1.5, and 2.0. The Reynolds number of the freestream was approximately 11,000 based on hole diameter. Thermocouple surveys were used to characterize the thermal field. Infrared thermography was used to determine the adiabatic film effectiveness on the plate. Hotwire anemometry was used to provide flowfield physics and turbulence measurements. The results are compared to existing data in the literature. The aim of this work is to produce a benchmark dataset for Computational Fluid Dynamics (CFD) development to eliminate the effects of hole length to diameter ratio and to improve resolution in the near-hole region. In this report, a Time Filtered Navier Stokes (TFNS), also known as Partially Resolved Navier Stokes (PRNS), method that was implemented in the Glenn-HT code is used to model coolant-mainstream interaction. This method is a high fidelity unsteady method that aims to represent large scale flow features and mixing more accurately.

Shyam, Vikram↗

DOE OSTI2023

The Effects of Channel Supplies on Overall Film-Cooling Effectiveness

Abstract Cooling components in the hot section of a gas turbine are essential to component durability. Common methods of cooling include rib turbulators in internal passages and film cooling on external surfaces. The holes that produce the film cooling are fed from the internal channels often containing ribs. Consequently, there is an interdependence of internal heat transfer and external film cooling. The purpose of this study was to obtain a better understanding of the interaction of ribs and film cooling. To quantify the cooling performance, the surface temperatures were measured, from which overall effectiveness was calculated. For the experiments, additively manufactured test coupons were made of Inconel 718 to match engine Biot numbers. These test coupons had internal feed channels with and without ribs and had both cylindrical holes and meter-diffuser-shaped holes with 15 deg lateral expansion angles and a 1 deg forward expansion angle. A single rectangular channel was one type of feed channel. The other type of feed channel was individual circular channels, with each circular channel supplying an individual film-cooling hole. The experimental results showed that the circular individual channels have 80% higher baseline overall effectiveness than the single rectangular channels without any film cooling. Ribbed turbulators without film cooling also increased the overall effectiveness by 21% for single rectangular channels and by 29% for the circular individual channels compared to the respective non-ribbed channels. While the film cooling increased the overall effectiveness of all geometries, the single rectangular channels had increased overall effectiveness levels by up to twice that of the no film-cooling case. On average, the single rectangular channels had an 80% improvement from film cooling, whereas the individual channel feeds, on average, had only a 50% improvement, given their high baseline effectiveness levels.

Engineering↗

NASA NTRS1971

Importance of combining convection with film cooling

The interaction of film and convection cooling and its effect on wall cooling efficiency is investigated analytically for two cooling schemes for advanced gas turbine applications. The two schemes are full coverage- and counterflow-film cooling. In full coverage film cooling, the cooling air issues from a large number of small discrete holes in the surface. Counterflow film cooling is a film-convection scheme with film injection from a slot geometry. The results indicate that it is beneficial to utilize as much of the cooling air heat sink as possible for convection cooling prior to ejecting it as a film.

Colladay, R. S.↗

NASA NTRS1972

Importance of combining convection with film cooling.

Colladay, R. S.↗

NASA NTRS1989

An experimental study of turbine vane heat transfer with leading edge and downstream film cooling

This paper presents the effects of downstream film cooling, with and without leading edge showerhead film cooling, on turbine-vane external heat transfer. Steady-state experimental measurements were made in a three-vane linear two-dimensional cascade. The principal independent parameters were maintained over ranges consistent with actual engine conditions. The test matrix was structured to provide an assessment of the independent influence of parameters of interest, namely, exit Mach number, exit Reynolds number, coolant-to-gas temperature ratio, and coolant-to-gas pressure ratio. The data obtained indicate that considerable cooling benefits can be achieved by utilizing downstream film cooling. The downstream film cooling process was shown to be a complex interaction of two competing mechanisms. The thermal dilution effect, associated with the injection of relatively cold fluid, results in a decrease in the heat transfer to the airfoil. Conversely, the turbulence augmentation, produced by the injection process, results in increased heat transfer to the airfoil.

Nirmalan, V.↗

NASA NTRS1977

Combustion effects on film cooling

The effects of: (1) a reactive environment on film cooling effectiveness, and (2) film cooling on rocket engine performance were determined experimentally in a rocket thrust chamber assembly operating with hydrogen and oxygen propellants at 300 psi chamber pressure. Tests were conducted using hydrogen, helium, and nitrogen film coolants in an instrumented, thin walled, steel thrust chamber. The film cooling, performance loss, and heat transfer coefficient data were correlated with the ALRC entrainment film cooling model which relates film coolant effectiveness and mixture ratio at the wall to the amount of mainstream gases entrained with the film coolant in a mixing layer. In addition, a comprehensive thermal analysis computer program, HOCOOL, was prepared from previously existing ALRC computer programs and analytical techniques.

Rousar, D. C.↗

NASA NTRS1996

Experimental Study of Vane Heat Transfer and Film Cooling at Elevated Levels of Turbulence

This report documents the results of an experimental study on the influence of high level turbulence on vane film cooling and the influence of film cooling on vane heat transfer. Three different cooling configurations were investigated which included one row of film cooling on both pressure and suction surfaces, two staggered rows of film cooling on both suction and pressure surfaces, and a shower-head cooling array. The turbulence had a strong influence on film cooling effectiveness, particularly on the pressure surface where local turbulence levels were the highest. For the single row of holes, the spanwise mixing quickly reduced centerline effectiveness levels while mixing in the normal direction was more gradual. The film cooling had a strong influence on the heat transfer in the laminar regions of the vane. The effect of film cooling on heat transfer was noticeable in the turbulent regions but augmentation ratios were significantly lower. In addition to heat transfer and film cooling, velocity profiles were taken downstream of the film cooling rows at three spanwise locations. These profile comparisons documented the strong spanwise mixing due to the high turbulence. Total pressure exit measurements were also documented for the three configurations.

Ames, Forrest E.↗

DOE OSTI2025

Simple Heat Transfer Model for Film Cooling Applications

This report describes the development of a simple engineering model for film cooling. This model is used to derive a relationship between local wall temperature variations and key cooling performance parameters like local heat transfer coefficients and film effectiveness. This relation and method new and different from previously published models. The scope of this report includes the derivation of regression model equations for a flat plate with and without film cooling. The model equation for a flat plate without film cooling can be used to estimate local heat transfer coefficients using surface temperatures measured from infrared thermography. The model equation for the flat plate with film cooling can be used to estimate film cooling effectiveness, $η_f$, and heat transfer augmentation from the film cooling jet(s).

42 ENGINEERING↗

DOE OSTI2024

Revisiting Dimensionless Parameters Quantifying Film Cooling

This paper describes a dimensional analysis of film cooling effectiveness for crossflow-fed film cooling holes. An additional parameter is required to account for swirl inside the film cooling hole. Computations based on Reynolds-Averaged Navier-Stokes (RANS) show significant improvements in cooling effectiveness when the coolant supply velocity is decreased. NETL experimental data was used to validate these computational results.

advanced gas turbines↗

NASA NTRS2018

Temperature Mapping Above and Below Air Film-Cooled Thermal Barrier Coatings Using Phosphor Thermometry

Thermal barrier coatings (TBCs) are typically used in conjunction with air film cooling to maximize overall cooling effectiveness and reliability while minimizing sacrifices in engine performance. The effects of thermal barrier coating (TBC) thermal protection and air film cooling effectiveness have usually been studied separately; however, their contributions to combined cooling effectiveness are interdependent and are not simply additive. The combined cooling effectiveness is always less than the sum of the cooling effectiveness of stand-alone TBC protection and stand-alone air film cooling. These diminishing returns arise because adding the thermally insulating TBC between the cooling air and the surface to be cooled reduces the air film cooling effectiveness and because the air film cooling reduces the heat flux through the TBC and therefore reduces the temperature difference sustained across the TBC thickness. Due to these considerations, combined cooling effectiveness must be measured to achieve an optimum balance between TBC thermal protection and air film cooling. In this investigation, temperature mapping above and below air film-cooled TBCs was performed using luminescence lifetime imaging-based phosphor thermometry. Measurements were performed in the NASA GRC Mach 0.3 burner rig on a TBC-coated plate using a scaled-up cooling hole geometry where both the hot mainstream gas temperature and the blowing ratio were varied. Surface temperature maps were obtained from a Cr-doped GdAlO3 thermographic phosphor deposited on the surface of the electron-beam vapor-deposited yttria-stabilized zirconia (YSZ) TBC. From separate plates, temperature maps from the bottom of the TBC were obtained from a thin Er-doped YSZ layer integrated into the TBC below the overlying undoped YSZ. Procedures for temperature and cooling effectiveness mapping above and below the air film-cooled TBC surface are described. Most importantly, these measurements enable mapping the combined cooling effectiveness below the TBC, which is more important than surface cooling effectiveness when there is a barrier coating between the hot mainstream gas and the surface that needs thermal protection. Advantages of the luminescence lifetime imaging method over infrared thermography, as well as its limitations to steady-state conditions are discussed.

cooling effectiveness.↗

NASA NTRS1997

Advanced Film Cooling Rig: Development and Test Results

The Advanced Film Cooling Rig (AFCR) test was a program to develop a thermal imaging camera system to measure the effectiveness of multihole film cooling. This system was used to evaluate low-thermal conductivity ceramic test panels incorporating a wide range of multihole cooling geometries. Tests were conducted with a mainstream flow of 600 F at Mach numbers of 0.37 and 1.57. Coolant flow was controlled to give a blowing parameter variation of up to 2.9. Data reduction techniques are given for camera calibration, rig temperature reflection correction, and deriving surface temperatures from video images. Results are presented in terms of overall and film cooling effectiveness distributions. A one-dimensional analysis of a unit film cooling hole was performed to generate film temperature.

Reilly, R. S.↗

NASA NTRS1975

Flow visualization of discrete hole film cooling for gas turbine applications

Film injection from discrete holes in a three row staggered array with 5-diameter spacing is studied. The boundary layer thickness-to-hole diameter ratio and Reynolds number are typical of gas turbine film cooling applications. Two different injection locations are studied to evaluate the effect of boundary layer thickness on film penetration and mixing. Detailed streaklines showing the turbulent motion of the injected air are obtained by photographing neutrally buoyant helium filled soap bubbles which follow the flow field. The bubble streaklines passing downstream injection locations are clearly identifiable and can be traced back to their origin. Visualization of surface temperature patterns obtained from infrared photographs of a similar film cooled surface are also included.

Colladay, R. S.↗

NASA NTRS1975

Flow visualization of discrete hole film cooling for gas turbine applications

Film injection from discrete holes in a three row staggered array with 5-diameter spacing is studied for three different hole angles: (1) normal, (2) slanted 30 deg to the surface in the direction of the mainstream, and (3) slanted 30 deg to the surface and 45 deg laterally to the mainstream. The boundary layer thickness-to-hole diameter ratio and Reynolds number are typical of gas turbine film cooling applications. Two different injection locations are studied to evaluate the effect of boundary layer thickness on film penetration and mixing. Detailed streaklines showing the turbulent motion of the injected air are obtained by photographing very small neutrally buoyant helium filled 'soap' bubbles which follow the flow field. Unlike smoke, which diffuses rapidly in the high turbulent mixing region associated with discrete hole blowing, the bubble streaklines passing downstream injection locations are clearly identifiable and can be traced back to their origin. Visualization of surface temperature patterns obtained from infrared photographs of a similar film cooled surface are also included.

Colladay, R. S.↗

NASA NTRS1975

Experimental verification of film-cooling concepts on a turbine vane

An investigation was conducted to verify some film cooling concepts applied to gas turbine vanes. The film cooling air was ejected from a single row of holes on the convex surface and a double row of holes of the concave surface. Tests were conducted at a gas temperature of 1260 K, a gas pressure of 3 atmospheres, and a coolant temperature of 280 K. Mass-velocity ratios were varied between 0 and 2.0. Data were taken without film-cooling holes, with film-cooling holes but without blowing, and with blowing. A small amount of blowing into a nonturbulent boundary layer caused an increase in vane temperatures. Film cooling when combined with convection cooling was verified to be more effective than either film or convective cooling alone.

Gladden, H. J.↗

NASA NTRS2022

Detailed Velocity, Temperature, and Heat Flux Measurements on a Large Scale Film Cooling Model

To investigate the flow physics of turbine film cooling, detailed mean and fluctuating velocity and temperature surveys were made in the turbulent jet flow field behind a row of large scale film cooling holes. Additionally, surface heat transfer, film effectiveness, and turbulent heat flux values were determined. Measurements were made in the NASA Engine Research Building (ERB) SW-6 test facility, which consists of an 8.15-in2 open-inlet wind tunnel with a temperature-controlled secondary flow system. The film-cooling test plate fit into the wind tunnel such that the heat transfer surface formed the wind tunnel floor. This plate consisted of a three-hole array of film cooling holes that were fed from a plenum of different temperature.

Fluid Mechanics↗

DOE OSTI2023

Experimental and Computational Investigation of Shaped Film Cooling Holes Designed to Minimize Inlet Separation

Abstract Film cooling is used to protect turbine components from the extreme temperatures by ejecting coolant through arrays of holes to create an air buffer from the hot combustion gases. Limitations in traditional machining meant film cooling holes universally have sharp inlets, which create separation regions at the hole entrance. The present study uses experimental and computational data to show that these inlet separation are a major cause of performance variation in crossflow fed film cooling holes. Three-hole designs were experimentally tested by independently varying the coolant velocity ratio (VR) and the coolant channel velocity ratio (VRc) to isolate the effects of crossflow on hole performance. Leveraging additive manufacturing (AM) technologies, the addition of a 0.25D radius fillet to the inlet of a 7-7-7 shaped hole is shown to significantly improve diffuser usage and significantly reduce variation in performance with VRc. A second AM design used a very large radius of curvature inlet to reduce biasing caused by the inlet crossflow. Experiments showed that this “swept” hole design did minimize biasing of the coolant flow to one side of the shaped hole, and it significantly reduced variations due to varying VRc. RANS simulations at six VR and three VRc conditions were made for each geometry to better understand how the new geometries changed the velocity field within the hole. The sharp and rounded inlets were seen to have very similar tangential velocity fields and jet biasing. Both AM inlets created more uniform, slower velocity fields entering the diffuser. The results of this article indicate that large improvements in film cooling performance can be found by leveraging AM technology.

Engineering↗

DOE OSTI2020

Performance of Public Film Cooling Geometries Produced Through Additive Manufacturing

Abstract Film cooling is an essential cooling technology to allow modern gas turbines to operate at high temperatures. For years, researchers in this community have worked to improve the effectiveness of film cooling configurations by maximizing the coolant coverage and minimizing the heat flux from the hot gas into the part. Working toward this goal has generated many promising film cooling concepts with unique shapes and configurations. However, until recently, many of these designs were challenging to manufacture in actual turbine hardware due to limitations with legacy manufacturing methods. Now, with the advances in additive manufacturing, it is possible to create turbine parts using high-temperature nickel alloys that feature detailed and unique geometry features. Armed with this new manufacturing power, this study aims to build and test the promising designs from the public literature that were previously difficult or impossible to implement. In this study, different cooling hole designs were manufactured in test coupons using a laser powder bed fusion process. Each nickel alloy coupon featured a single row of engine scale cooling holes, fed by a microchannel. To evaluate performance, the overall cooling effectiveness of each coupon was measured using a matched Biot test at engine relevant conditions. The results showed that certain hole shapes are better suited for additive manufacturing than others and that the manufacturing process can cause significant deviations from the performance reported in the literature.

Engineering↗