Continuous use of internal cooling to suppress knock in aircraft engines cruising at high power
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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
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Neutron Characterization of 3D Printed Gas Turbine Alloy With Internal Cooling Structure
The objective of this research work is to investigate the residual strains induced by the presence of a exit hole and internal hollow geometry present in a 3D printed IN718 similar to that seen in a gas turbine blade. The specimens were manufactured with an internal hollow structure that ended with an exit hole, and fabricated by direct metal laser sintering additive manufacturing technique. Using this technique, metal powder was melted by a laser source and rapidly cooled to form the part layer by layer. Rapid heating and cooling generate large thermal gradients and residual stresses in the 3D printed material. To be aligned with industry standards, specimens were heat-treated to relieve most of the residual stresses as well as to investigate whether IN718 still preserved a nonhomogeneous stress state after the thermal treatment. Roughness and microstructure analysis was performed to understand the heat-treated sample properties. To investigate the volumetric residual strain, the neutron diffraction technique was used with a definite neutron wavelength. Bragg’s law was used to determine lattice spacing. Interplanar lattice spacing and stress-free state lattice spacings were measured to calculate the strains. Residual strains were measured in the x and y direction to understand the impact of the presence of a exit hole and internal hollow geometry. The results of volumetric residual strain in the x and y directions showed no significant variations in the distribution of the strain due to the presence of a hollow structure as well as the exit hole. Overall, no significant stress concentration was observed in the heat treated sample. Sample geometry, instrumentation for neutron diffraction, and material properties are discussed in detail in this paper.
Raju, Nandhini↗
Impact of Additive Manufacturing on Internal Cooling Channels With Varying Diameters and Build Directions
Abstract The use of additive manufacturing (AM) processes, such as direct metal laser sintering, provides the design freedom required to incorporate complex cooling schemes in gas turbine components. Additively manufactured turbine components have a range of cooling feature sizes and, because of the inherent three-dimensionality, a wide range of build angles. Previous studies have shown that AM built directions influence internal channel surface roughness that, in turn, augment heat transfer and pressure loss. This study investigates the impact of AM on channel feature size and builds direction relative to tolerance, surface roughness, pressure losses, and convective cooling. Multiple AM coupons were built from Inconel 718 consisting of channels with different diameters and a variety of build directions. An experimental rig was used to measure pressure drop to calculate friction factor and was used to impose a constant surface temperature boundary condition to collect Nusselt number over a range of Reynolds numbers. Significant variations in surface roughness and geometric deviations from the design intent were observed for distinct build directions and channel sizes. These differences led to notable impacts in friction factor and Nusselt number augmentations, which were a strong function of build angle.
Engineering↗
Internal cooling increases range of immersion-type temperature probe
Temperature probe used in a high temperature, high velocity gas stream consists of cooled outer shell and a cooled platinum sensing tube with iron constantan thermocouples.
Lanzo, C. D.↗
Strain-gage Study of Internally Cooled Exhaust Valves Having Various Throat Designs
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Faldetta, Richard D↗
Analytical and experimental investigation of a forced-convection air-cooled internal strut-supported turbine blade
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Shum, Eugene F↗
Internal cooling passages for rotating cutting tools
A cutting tool comprising a tool body comprising a shank and a cutter opposite the shank, the body defining a length from a shank end to an end face opposite the shank end, a central axis extends along the length of the body; at least one tooth having a cutting edge, the cutting edge extending along the tooth from the shank to the end face; a flute formed adjacent the at least one tooth; at least one cooling channel formed in the tooth proximate the at least one cutting edge, the at least one cooling channel having an elongated cross sectional shape with an elliptical portion and a circular portion opposite the elliptical portion, wherein the elliptical portion is located proximate the cutting edge.
Wang, Zhigang↗
Airfoil having internally cooled wall with liner and shell
An airfoil includes an airfoil section that has an airfoil wall that surrounds a cavity. The airfoil wall includes a first wall section comprised of a monolithic ceramic shell, a second wall section comprised of a CMC liner that is bonded along an interface to an interior side of the monolithic ceramic shell, and a ceramic barrier coating that is bonded to an exterior side of the monolithic ceramic shell. The airfoil wall includes at least one of: inter-section cooling channels that extend along the interface and are bounded by the monolithic ceramic shell and the CMC liner, or intra-section cooling channels that extend within the CMC liner.
Croteau, Paul F.↗
Novel Additively Manufactured and Internally Cooled Airfoils for Increasing Small Industrial Gas Turbine Efficiency
ASME Turbo Expo 2023
Searle, Matthew↗
Overall Cooling Effectiveness With Internal Serpentine Channels and Optimized Film Cooling Holes
Abstract The overall cooling effectiveness for gas turbine airfoils is a function of the combined cooling due to internal cooling configurations and film cooling configurations. Typically, film cooling configurations are evaluated independent of the cooling effects of the internal feed channels, generally based on adiabatic effectiveness measurements. In this study, we consider the coupled effects of internal cooling and film cooling configurations through measurements of overall cooling effectiveness for film cooling holes fed by a coflow/counterflow channel and a serpentine channel. A film cooling hole designed by adjoint optimization techniques (X-AOpt) is compared to a standard-shaped hole with 7 deg forward and lateral expansions (7-7-7 SI). Experiments without film cooling showed that the serpentine channel had 35–50% greater overall cooling effectiveness than the straight, coflow channel. Experiments with the X-AOpt hole combined with a serpentine channel showed an area-averaged overall cooling effectiveness of ϕ¯¯=0.58, which was a 70% increase compared to the overall cooling effectiveness of the serpentine channel without film cooling. When the X-AOpt hole was fed with a coflow channel with similar coolant mass flowrate, the overall cooling effectiveness was ϕ¯¯=0.44, i.e., 30% lower than when using the serpentine channel. Interestingly, adiabatic effectiveness measurements with the X-AOpt holes showed a more uniform hole-to-hole performance when using the serpentine channel compared to the coflow channel.
Engineering↗
Experimental and Large Eddy Simulation Study for Visualizing Complex Flow Phenomena of Gas Turbine Internal Blade Cooling Channel With No Bend
Abstract In this study, the internal cooling channel was investigated without any bend. Smooth surfaces and dimpled surfaces were investigated using the different combinations of connecting circular and rectangular holes. The computations were performed using the large eddy simulation (LES) model for Reynolds (Re) numbers from 10,000 to 50,000. A total of six different connecting holes were investigated with a smooth and dimpled surface. A partial spherical dimple with two circular holes showed the highest heat transfer, but it has a higher pressure loss penalty. Even though the leaf dimpled surface with the rectangluar holes indicated a little low heat transfer, it represents the highest efficiency at higher Reynolds numbers because of the low-pressure drops.
Energy & Fuels↗
Internal convective cooling systems for hypersonic aircraft
Parametric studies were conducted to investigate the relative merits of construction materials, coolants, and cooled panel concepts for internal convective cooling systems applied to airframe structures of hydrogen-fueled hypersonic aircraft. These parametric studies were then used as a means of comparing various cooled structural arrangements for a hypersonic transport and a hypersonic research airplane. The cooled airplane studies emphasized weight aspects as related to the choice of materials, structural arrangements, structural temperatures, and matching of the cooling system heat load to the available hydrogen fuel-flow heat sink. Consideration was given to reliability and to fatigue and fracture aspects, as well. Even when auxiliary thermal protection system items such as heat shielding, insulation, and excess hydrogen for cooling are considered the more attractive actively cooled airframe concepts indicated potential payload increases of from 40 percent to over 100 percent for the hypersonic transport as compared to the results of previous studies of the same vehicle configuration with an uncooled airframe.
Anthony, F. M.↗
Experimental and Computational Investigation of Integrated Internal and Film Cooling Designs Incorporating a Thermal Barrier Coating
Abstract Few studies in the open literature have studied the effect of thermal barrier coatings (TBC) when used in combination with shaped hole film cooling and enhanced internal cooling techniques. The current study presents Reynolds-averaged Navier–Stokes (RANS) conjugate heat transfer simulations that identify trends in cooling design performance as well as experimental measurements of overall effectiveness using a flat-plate matched-Biot number model with a simulated TBC layer of 0.42D thickness, where D is the film cooling hole diameter. Coolant is fed to the film cooling holes in a co-flow configuration, and the results of both the smooth and rib-turbulated channels are compared. At a constant coolant flow rate, enhanced internal cooling was found to provide a 44% increase in spatially-averaged overall effectiveness, $\bar{\bar{\phi}}$, without a TBC. The results show that the addition of a TBC can raise $\bar{\bar{\phi}}$ on a film-cooled component surface by 47%. The optimum velocity ratio was found to decrease with the addition of enhanced cooling techniques and a TBC as the film provided minimal benefit at the expense of reduced internal cooling. While the computational results closely identified trends in overall system performance without a TBC, the model over-predicted effectiveness on the metal–TBC interface. The results of this study will inform turbine component design as material science advances increase the reliability of the TBC.
Engineering↗
Hydrogen film/conductive cooling
Small scale nozzle tests using heated nitrogen were run to obtain effectiveness and wall heat transfer data with hydrogen film cooling. Effectiveness data are compared with an entrainment model developed from planar, unaccelerated flow data. Results indicate significant effects due to flow turning and acceleration. With injection velocity effects accounted for explicitly, heat transfer correlation coefficients were found to be the same with and without film cooling when properties are evaluated at an appropriate reference temperature for the local gas composition defined by the coolant effectiveness. A design study for an O2/H2 application with 300 psia (207 N/sq cm) chamber pressure and 1500 lbs (6670 N) thrust indicates an adiabatic wall design requires 4 to 5 percent of the total flow as hydrogen film cooling. Internal regenerative cooling designs were found to offer no reduction in coolant requirements.
Ewen, R. L.↗
Turbulence modeling needs of commercial CFD codes: Complex flows in the aerospace and automotive industries
This viewgraph presentation discusses the following: STAR-CD computational features; STAR-CD turbulence models; common features of industrial complex flows; industry-specific CFD development requirements; applications and experiences of industrial complex flows, including flow in rotating disc cavities, diffusion hole film cooling, internal blade cooling, and external car aerodynamics; and conclusions on turbulence modeling needs.
Befrui, Bizhan A.↗
Heat Transfer in Gas Turbines
The turbine gas path is a very complex flow field. This is due to a variety of flow and heat transfer phenomena encountered in turbine passages. This manuscript provides an overview of the current work in this field at the NASA Glenn Research Center. Also, based on the author's preference, more emphasis is on the computational work. There is much more experimental work in progress at GRC than that reported here. While much has been achieved, more needs to be done in terms of validating the predictions against experimental data. More experimental data, especially on film cooled and rough turbine blades, are required for code validation. Also, the combined film cooling and internal cooling flow computation for a real blade is yet to be performed. While most computational work to date has assumed steady state conditions, the flow is clearly unsteady due to the presence of wakes. All this points to a long road ahead. However, we are well on course.
Garg, Vijay K.↗
Effects of additively manufactured surface roughness on small diameter plenums with multiple side discharges for high temperature gas turbine blade cooling applications
Combined heat and power (CHP) applications have significant environmental and economic benefits that are consistent with the goals of the U.S. Department of Energy (DOE). One area that is currently being studied includes the potential benefits of CHP turbine operation at higher turbine inlet temperatures. Internal cooling concepts enabled by additive manufacturing (AM) are of primary interest. Here, the effectiveness of internal cooling is hindered by many factors such as velocity distribution of the cooling air to the hot surface considering impingement cooling. To simulate cooling air exiting from a series of orifices for internal cooling in an airfoil, a straight smooth wall tubing with multiple side discharging orifices is used and compared to additively manufactured tubing (Ti6Al4V Grade 23) with orifice size and spacing as well as inner and outer diameters identical to the smooth wall tubing. Similar to flow discharging form perforated pipes, the flow discharged from individual orifices along the tubes in this study is found to be nonuniformly distributed, and the horizontal (axial direction) momentum can be observed from the experimental data. Discharge velocities have been measured with two-dimensional (2D) particle imaging velocimetry (PIV) and single element hot wire anemometry. Numerical analysis has also been conducted to predict the velocity distributions along the orifices in the smooth wall and additive manufacturing (AM) tubing, which are inherited with surface roughness. Numerical and measured results in this study are compared, presented, and discussed.
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗