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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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At least 829 records · Page 46
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Estimation of Minimum Spouting Velocity in a Rectangular Spouted Bed

Here, a study was conducted to explore the effects of static bed height, nozzle diameter, cone angle, and particle properties on the minimum spouting velocity in a 4 in × 1 in rectangular spouted bed. Tests were conducted with various solids materials (including 871 μm HPDE pellets, 3.2 mm nylon beads, 707 μm glass beads, and 1.5 mm alumina spheres), two gas inlet nozzle diameters, and two cone angles. Experimentally obtained minimum spouting velocities were compared to existing published correlations developed for cylindrical spouted beds. In each case, it was determined that the existing correlations did not adequately predict the minimum spouting velocity for a rectangular spouted bed. A new correlation is proposed.

36 MATERIALS SCIENCE↗
DOE OSTI2018

High-Performance Computing and Analysis-Led Development of High Efficiency Dilute Opposed Piston Gasoline Engine

Pinnacle is developing a multicylinder 1.2 L gasoline engine for automotive applications using high-performance computing (HPC) and analysis methods. Pinnacle and Oak Ridge National Laboratory executed large-scale multidimensional combustion analyses at the Oak Ridge Leadership Computing Facility to thoroughly explore the design space. These HPC-led investigations show high fuel efficiency (~46% gross indicated efficiency) may be achieved by operating with extremely high charge dilution levels of exhaust gas recirculation (EGR) at a light load key drive cycle condition (2000 RPM, 3 bar brake mean effective pressure (BMEP)), while simultaneously attaining high levels of fuel conversion efficiency and low NO x emissions. In this extremely dilute environment, the flame propagation event is supported by turbulence and bulk in-cylinder charge motion brought about by modulation of inlet port flow. This arrangement produces a load and speed adjustable amalgamation of swirl and counter-rotating tumble which provides the turbulence required to support stable low-temperature combustion. At higher load conditions, the engine may operate at more traditional combustion modes to generate competitive power. In this work, the numerical results from these HPC simulations are presented. Finally, further HPC simulations and test validations are underway and will be reported in future publications.

42 ENGINEERING↗
DOE OSTI2018

Hybrid-Electric Turbocharger and High-Speed SiC Variable-Frequency Drive Using Sensorless Control Algorithm

Electrically assisted engine boosting systems lend themselves to better throttle response, wider effective operating ranges, and can provide the ability to extract excess energy during deceleration and high-load events (and store it in a vehicle's onboard batteries). This can lead to better overall vehicle performance, emissions, and efficiency while allowing for further engine downsizing and increased power density. In this research effort, a hybrid-electric turbocharger, variable-frequency drive (VFD), and novel sensorless control algorithm were developed. An 11 kW permanent-magnet (PM) machine was coupled to a commercial turbocharger via an in-line, bolt-on housing attached to the compressor inlet. A high-efficiency, high-temperature VFD, consisting of custom control and power electronics, was also developed. The VFD uses SiC MOSFETS to achieve high-switching frequency and can be cooled using an existing engine coolant loop operating at up to 105 °C at an efficiency greater than 98%. A digital sliding mode-observer sensorless speed control algorithm was created to command and regulate speed and achieved ramp rates of over 68,000 rpm/s. A two-machine benchtop motor/generator test stand was constructed for initial testing and tuning of the VFD and sensorless control algorithm. A gas blow-down test stand was constructed to test the mechanical operation of the hybrid-electric turbocharger and speed control using the VFD. In addition, a liquid-pump cart was assembled for high-temperature testing of the VFD. Initial on-engine testing is planned for later this year. This paper intends to present a design overview of the in-line, hybrid-electric device, VFD, and performance characterization of the electronics and sensorless control algorithm.

Engineering↗
DOE OSTI2019

Large Eddy Simulation of the Flow Behavior in a Simplified Helical Coil Steam Generator

Large eddy simulation (LES) is conducted for the flow over the shell side of a helical coil steam generator (HCSG) heat exchanger. Simulations are conducted on a simplified experimental test section that represents a one-column region of the helical coils using half-rods. Although the rods are wall-bounded, the flow still exhibits the turbulent characteristics and fluctuations from vortex shedding that one would expect from crossflow around a cylinder. The spectral element, computational fluid dynamics (CFD) code Nek5000, is used to capture the physics, and the results are compared with particle image velocimetry (PIV) measurements. In order to ensure that the turbulence is resolved, analysis is conducted by using the Taylor length scales and normalized wall distance. Sensitivity to the inlet boundary conditions (BCs) and the spatial discretization for different polynomial order solutions are also studied, finding only minor differences between each case. Pressure drop and velocity statistics show reasonable agreement with PIV. Proper orthogonal decomposition (POD) analysis reveals that the primary modes are similar between experiment and simulation, although the LES predicts higher turbulent kinetic energy than does PIV. Overall, the study establishes the resolution and resources required in order to conduct a high-fidelity simulation over 12 helical rods.

Lai, Jonathan K.↗
DOE OSTI2019

A General Study of Counterflow Diffusion Flames for Supercritical CO2 Combustion

Abstract A counterflow diffusion flame for supercritical CO2 combustion is investigated at various CO2 dilution levels and pressures by accounting for real gas effects into both thermal and transport properties. The UCF 1.1 24-species mechanism is used to account the chemistry. The nature of important nonpremixed combustion characteristics such as Prandtl number, thermal diffusivity, Lewis number, stoichiometric scalar dissipation rate, flame thickness, and Damköhler number are investigated with respect to CO2 dilution and pressure. The results show that the aforementioned parameters are influenced by both dilution and pressure; the dilution effect is more dominant. Further, the result shows that Prandtl number increases with CO2 dilution and at 90% CO2 dilution, the difference between the Prandtl number of the inlet jets and the flame is minimal. Also, the common assumption of unity Lewis number in the theory and modeling of nonpremixed combustion does not hold reasonable for sCO2 applications due to large difference of Lewis number across the flame and the Lewis number on the flame drop significantly with an increase in the CO2 dilution. An interesting relation between Lewis number and CO2 dilution is observed. The Lewis number of species drops by 15% when increasing the CO2 dilution by 30%. Increasing the CO2 dilution increases both the flow and chemical timescales; however, chemical timescale increases faster than the flow timescales. The magnitudes of the Damköhler number signify the need to consider finite rate chemistry for sCO2 applications. Further, the Damköhler numbers at 90% sCO2 dilution are very small; hence, laminar flamelet assumptions in turbulent combustion simulations are not physically correct for this application. Also, it is observed that the Damköhler number drops nonlinearly with increasing CO2 dilution in the oxidizer stream. This is a very important observation for the operation of sCO2 combustors. Further, the flame thickness is found to increase with CO2 dilution and reduce with pressure.

Engineering↗
DOE OSTI2020

Measurements of Density and Sound Speed in Mixtures Relevant to Supercritical CO2 Cycles

Abstract The objective of this research is to validate properties of mixtures relevant to supercritical carbon dioxide (sCO2) power cycles. Direct-fired sCO2 cycles are a promising technology for the future power generation systems. The working fluid of sCO2 cycles will be near and above critical point of CO2. One of the challenges is that the simulation of mixtures should consider real gas behavior. Expected operating conditions of Allam cycles reach up to 300 bar and 1000 °C. Characterizing the mixtures at the extreme conditions is an important issue in current researches and industrial applications. Thermophysical properties of mixtures may be beyond the valid range of the widely used database such as NIST REFPROP. Experimental data of mixture properties in the literature are limited which is necessary to develop high-fidelity design tools for sCO2 power cycles. We measured the density and sound speed of several multi-component mixtures. A temperature-controlled high-pressure test cell was used for the density measurements. Sound speed was measured by resonant frequency detection using an external speaker and a piezoelectric pressure sensor. Mixtures studied in this work include carbon dioxide, methane, oxygen, and water vapor. Properties of pure CO2 were measured to show the validity of our technique. Compositions were selected to be close to frozen mixtures at the inlet, mid-progress, and exhaust conditions of a model sCO2 combustor in the previous numerical simulation work. Corresponding reaction progress variables (RPV) were RPV = 0, 0.5, and 1. Temperature and pressure conditions of experiments are 310–450 K and 0–150 bar. In our study, density and sound speed from the NIST REFPROP database agree with experimental measurements within the range of our measurement uncertainties.

Energy & Fuels↗
DOE OSTI2021

Evaluating the Effects of Transient Purge Flow on Stator-Rotor Seal Performance

Abstract As modern engine designs target higher efficiencies through increased turbine inlet temperatures, critical turbine components are at increased risk of damage from conditions exceeding material melting temperatures. In particular, improperly designed underplatform hardware components are susceptible to damage when hot main gas path flow is ingested into the stator-rotor cavity. While all turbines inherently experience transients during operation, a majority of publicly available turbine studies have been executed using steady operating conditions or inherently transient “blowdown” rigs. For this reason, routine transient events are not well understood. To address this need, the present study utilized a combined experimental and computational approach. The test article is a continuous-duration, one-stage test turbine operating with true-scale engine hardware and seal geometries at engine-representative flow conditions. The nature of the continuous-duration facility uniquely supports the direct assessment of transient events through its ability to transition between steady-state operating conditions. The effects of a transient purge flow were investigated in this study to identify general trends for transient events in a full-scale engine. Results from multiple measurement techniques in the wheelspace region show an interdependence of transient purge flow with a thermal lag of the underplatform hardware. Through experiments conducted at different coolant-to-main gas path temperature ratios, the use of pressure measurements as an indicator of fully purged behavior was introduced, and a thermally driven influence on rim seal performance was quantified. The computational results show good agreement with experimental pressure measurements and provide insight into the physical mechanisms that drive the relationship between pressure and sealing effectiveness measurements observed for the tested geometry.

Engineering↗
DOE OSTI2021

The Effect of Pressure on NO x Entitlement and Reaction Timescales in a Premixed Axial Jet-In-Crossflow

This paper investigates the pressure dependency of a lean premixed jet injected into a lean vitiated crossflow with an experimentally verified detailed chemistry computational fluid dynamics (CFD) model and 53 species considered. Experimental data were taken in an axially staged combustor with an optically accessible test section, allowing the use of particle image velocimetry (PIV) and CH* chemiluminescence techniques as well as point measurement of species concentration, temperature, and pressure. The experimental data cases at one, three, and five atmospheres were selected to describe the flame stabilization dependency on pressure and gain the required knowledge for an extrapolation to engine condition. Simulated exit nitrogen oxide levels were validated with experimental emission data, and a global emission trend for the NO reduction at elevated pressure and constant turbine inlet temperature level was defined. The nitrogen oxide benefit at elevated operating pressure was justified with the significantly smaller flame surface area: the analysis of the simulated spanwise and top-view profiles showed a relatively short receded core flame with nitrogen oxide production in the center at high pressure relative to a longer and larger shear layer flame at atmospheric condition that produced NO toward the inner and outer side of the flame. Furthermore, decomposition of the Damköhler number revealed the strong influence of the reaction timescales with higher reaction rates at elevated pressure, along with a moderate influence of the turbulent timescales, showing higher turbulence intensity in the lee-side recirculation zone at lower pressure.

03 NATURAL GAS↗
DOE OSTI2021

A Method to Design and Optimize Axial Flow Cyclones for Gas–Liquid Separation

This article provides a detailed design guide, optimization, and performance assessment for air–water separation of an axial flow cyclone. Axial flow cyclones (also known as swirl tube demisters, mist eliminators, or Austin–Write cyclones) have a range of applications in several different industries. This method of gas–liquid separation offers many benefits. Among these are high liquid separation efficiencies (near 99%) and an inline design that allows them to be more easily fitted into existing piping structures. Despite these benefits, there are several design parameters that have not been optimized for performance in wastewater purification applications. This research fills the gap in the literature by quantifying the effect of new design parameters on water collection efficiency, η water collection , and the air bypass efficiency, η air bypass , defined as the ratio of the air mass flowrate exiting through the desired air outlet over the inlet air mass flowrate. A set of wide-ranging experiments were conducted to study the effects of gas–liquid flow rates, tube geometry, and relative injection angles to optimize the water collection and air bypass efficiencies. The water collection efficiency exceeded 99.8% when the liquid streamline came in direct contact with the water drainage exit. An empirical correlation was developed to predict the swirl pitch as a function of the above design parameters. Predictions from the correlation were within 10% of the experimental results. The correlation can be used to design highly efficient in-line gas–liquid separators.

Engineering↗
DOE OSTI2021

Additively Manufactured Compliant Hybrid Gas Thrust Bearing for Supercritical Carbon Dioxide Turbomachinery: Design and Proof of Concept Testing

The following paper presents a new type of gas lubricated thrust bearing that utilizes additive manufacturing or also known as direct metal laser melting (DMLM) to fabricate the bearing. The motivation for the new bearing concept is derived from the need for highly efficient supercritical carbon dioxide (sCO2) turbomachinery in the mega-watt power range. The paper provides a review of existing gas thrust-bearing technology, outlines the need for the new DMLM concept, and discusses proof-of-concept testing results. The new concept combines hydrostatic pressurization with individual tilting pads that are flexibly mounted using hermetic squeeze film dampers (HSFD) in the bearing-pad support. This paper describes the thrust-bearing concept and discusses the final design approach. Proof-of-concept testing in air for a 6.8 in. (173 mm) outer diameter thrust gas bearing was performed; with thrust loading, up to 1500 lbs (6.67 kN) and a thrust runner speed of 10krpm (91 m/s tip speed). The experiments were performed with a bent shaft resulting in thrust runner axial vibration magnitudes of 2.9 mils (74 μm) p-p and dynamic thrust loads of 270 lbs (1.2 kN) p-p. In addition, force deflection characteristics and stiffness coefficients of the bearing system are presented for an inlet hydrostatic pressure of 380 psi (2.62 MPa). Results at 10 krpm show that the pad support architecture was able to sustain high levels of dynamic misalignment equaling 6 times the nominal film clearance while demonstrating a unit load-carrying capacity of 55 psi (0.34 Mpa). Gas-film force deflection tests portrayed nonlinear behavior like a hardening spring, while the bearing pad support stiffness was measured to be linear and independent of gas film thickness.

Engineering↗
DOE OSTI2021

Ultra-High Temperature Thermal Conductivity Measurements of a Reactive Magnesium Manganese Oxide Porous Bed Using a Transient Hot Wire Method

Pelletized magnesium manganese oxide shows promise for high temperature thermochemical energy storage. It can be thermally reduced in the temperature range between 1250 °C and 1500 °C and re-oxidized with air at typical gas-turbine inlet pressures (1–25 bar) in the temperature range between 600 °C and 1500 °C. The combined thermal and chemical volumetric energy density is approximately 2300 MJ/m3. The rate at which a thermochemical storage module can be charged is limited by heat transfer inside the solid packed bed. Hence, the effective thermal conductivity of packed beds of magnesium-manganese oxide pellets is a crucial parameter for engineering Mg-Mn-O redox storage devices. We have measured the effective thermal conductivity of a packed bed of 3.66 ± 0.516 mm sized magnesium manganese oxide (Mn to Mg molar ratio of 1:1) pellets in the temperature range of 300–1400 °C. Since the material is electrically conductive at temperatures above 600 °C, the sheathed transient hot wire method is used for measurements. Raw data is analyzed using the Blackwell solution to extract the bed thermal conductivity. The effective thermal conductivity standard deviation is less than 10% for a minimum of three repeat measurements at each temperature. Experimental results show an increase in the effective thermal conductivity with temperature from 0.50 W/m °C around 300 °C to 1.81 W/m °C close to 1400 °C. We propose a dual porosity model to express the effective thermal conductivity as a function of temperature. This model also considers the effect of radiation within the bed, as this is the dominant heat transfer mode at high temperatures. The proposed model accounts for microscale pellet porosity, macroscale bed porosity, pellet size, solid thermal conductivity (phonon transport), and radiation (photon transport). The coefficient of determination between the proposed model and the experimental results is greater than 0.90.

Engineering↗
DOE OSTI2022

Three-Dimensional Permeability of Thick-Section Glass Fabric Reinforced Polymer Composite by Vacuum-Assisted Resin Infusion Molding

Abstract Determination of permeability of thick-section glass fabric preforms with fabric layers of different architectures is critical for manufacturing large, thick composite structures with complex geometry, such as wind turbine blades. The thick-section reinforcement permeability is inherently three-dimensional and needs to be obtained for accurate composite processing modeling and analysis. Numerical simulation of the liquid stage of vacuum-assisted resin infusion molding (VARIM) is important to advance the composite manufacturing process and reduce processing-induced defects. In this research, the 3D permeability of thick-section E-glass fabric reinforcement preforms is determined, and the results are validated by a comparison between flow front progressions from experiments and from numerical simulations using ansys fluent software. The orientation of the principal permeability axes were unknown prior to experiments. The approach used in this research differs from those in literature in that the through-thickness permeability is determined as a function of flow front positions along the principal axes and the in-plane permeabilities and is not dependent on the inlet radius. The approach was tested on reinforcements with fabric architectures which vary through-the-thickness direction, such as those in a spar cap of a wind turbine blade. The computational simulations of the flow-front progression through-the-thickness were consistent with experimental observations.

Engineering↗
DOE OSTI2022

High-Fidelity Simulation Study of the Unsteady Flow Effects on High-Pressure Turbine Blade Performance

Abstract Unsteadiness, in the form of both broadband background disturbances and discrete coherent wakes, can have a strong effect on the performance of turbomachinery blades. The influence of the incoming flow has received much interest as it inevitably affects the blade boundary layers and develops as it passes through the machine. In the present work, we investigate the effect of unsteady flow on high-pressure turbines (HPTs), using high-fidelity datasets produced by wall resolved large-eddy simulation of an HPT stage. The effects of incident wakes from an upstream stator, compounded by the presence of freestream turbulence, on the downstream rotor are investigated. Based on analyzing cases with different turbulence intensities and length scales prescribed at the inlet, we show that changing the freestream turbulence characteristics has a direct effect on the unsteady behavior of the stator wakes. As a result, the performance of the rotor is also significantly affected. By detailing the influence of the wake–turbulence interaction, we aim to distinguish driving forces on rotor performance, be it changes in the incident wakes or direct influence from the freestream turbulence. Furthermore, the aerothermal behaviors of the rotor blades have been extensively investigated, showing that the blade boundary layers on the suction and pressure sides respond differently to external disturbances. The insights gained can provide designers with guidelines in understanding the unsteady flow effects of a given flow state, and how the unsteadiness present, either broadband or deterministic, will affect the performance of downstream blades.

Engineering↗
DOE OSTI2022

Calculation of Nuclear Reactor Cooling Tower Performance With Limited Data Streams

Monitoring of cooling tower performance in a nuclear reactor facility is necessary to ensure safe operation; however, instrumentation for measuring performance characteristics can be difficult to install and may malfunction or break down over long duration experiments. This paper describes employing a thermodynamic approach to quantify cooling tower performance, the Merkel model, which requires only five parameters, namely, inlet water temperature, outlet water temperature, liquid mass flowrate, gas mass flowrate, and wet bulb temperature. Using this model, a general method to determine cooling tower operation for a nuclear reactor was developed in situations when neither the outlet water temperature nor gas mass flowrate are available, the former being a critical piece of information to bound the Merkel integral. Furthermore, when multiple cooling tower cells are used in parallel (as would be in the case of large-scale cooling operations), only the average outlet temperature of the cooling system is used as feedback for fan speed control, increasing the difficulty of obtaining the outlet water temperature for each cell. To address these shortcomings, this paper describes a method to obtain individual cell outlet water temperatures for mechanical forced-air cooling towers via parametric analysis and optimization. In this method, the outlet water temperature for an individual cooling tower cell is acquired as a function of the liquid-to-gas ratio (L/G). Leveraging the tight tolerance on the average outlet water temperature, an error function is generated to describe the deviation of the parameterized L/G to the highly controlled average outlet temperature. The method was able to determine the gas flowrate at rated conditions to be within 3.9% from that obtained from the manufacturer’s specification, while the average error for the four individual cooling cell outlet water temperatures were 1.6 °C, -0.5 °C, -1.0 °C, and 0.3 °C.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2023

Tree-Based Ensemble Learning Models for Wall Temperature Predictions in Post-Critical Heat Flux Flow Regimes at Subcooled and Low-Quality Conditions

Accurately predicting post-critical heat flux (CHF) heat transfer is an important but challenging task in water-cooled reactor design and safety analysis. Although numerous heat transfer correlations have been developed to predict post-CHF heat transfer, these correlations are only applicable to relatively narrow ranges of flow conditions due to the complex physical nature of the post-CHF heat transfer regimes. In this paper, a large quantity of experimental data is collected and summarized from the literature for steady-state subcooled and low-quality film boiling regimes with water as the working fluid in vertical tubular test sections. In addition, a low-quality water film boiling (LWFB) database is consolidated with a total of 22,813 experimental data points, which cover a wide flow range of the system pressure from 0.1 to 9.0 MPa, mass flux from 25 to 2750 kg/m 2 s, and inlet subcooling from 1 to 70 °C. Two machine learning (ML) models, based on random forest (RF) and gradient boosted decision tree (GBDT), are trained and validated to predict wall temperatures in post-CHF flow regimes. The trained ML models demonstrate significantly improved accuracies compared to conventional empirical correlations. To further evaluate the performance of these two ML models from a statistical perspective, three criteria are investigated and three metrics are calculated to quantitatively assess the accuracy of these two ML models. For the full LWFB database, the root-mean-square errors between the measured and predicted wall temperatures by the GBDT and RF models are 5.7% and 6.2%, respectively, confirming the accuracy of the two ML models.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Influence of Correlations on the Thermal Performance Modeling of Parabolic Trough Collectors

The influence of correlations on the thermal performance modeling of parabolic trough collectors was analyzed in this work. A versatile model for a parabolic trough collector was developed that allows one- and two-dimensional analysis and enables the use of correlations to calculate thermophysical properties and convection heat transfer coefficients. The model also allows the use of constant values for properties and/or coefficients obtained from the evaluation correlations at a specific temperature. The effect of each correlation was evaluated independently, and the results were compared with a reference case that considered a two-dimensional approach and used all the correlations. For the analyzed cases, the correlation for the absorber emittance has the strongest impact on the collector efficiency, leading to a lower error when used. Based on the results, a one-dimensional model approach considering a correlation for the absorber emittance leads to efficiency errors below 3% for collector lengths of up to 243.6 m. Compared with the reference case, a one-dimensional approach using all correlations for a collector with a length of 500 m, and operating with an inlet temperature of 773 K, can result in errors around 9%. However, using constant values for properties and heat transfer coefficients could lead to errors of up to 50%. Multiple thermal models for parabolic trough collectors proposed in the literature rely on a one-dimensional approach, estimated values for the heat transfer coefficients, and constant thermophysical properties. The errors associated with those approaches are analyzed and quantified in this work as a function of the collector length and operation temperature.

absorber emittance↗
DOE OSTI2023

Manufacturing and Hydro Testing of a 10 MWe sCO2 Axial Turbine

Abstract Supercritical CO2 (sCO2) power cycles designed for thermodynamic efficiencies above 50% push component designs into pressure and temperature combinations that approach the limits of American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code and ASME Piping Design Codes with Turbine inlet conditions near 250 bar and 715 °C. These design conditions which limit available materials to high nickel alloys are compounded by the high fluid densities of sCO2 at these conditions which result in very compact machinery at the 10 MWe class which are currently being developed for the DOE supercritical transformational electric power (STEP) program. Design of the STEP Turbine is complete with integrated lessons learned from a previous 1 MWth subscale demonstration of a high temperature 10 MWe Turbine designed under the DOE SunShot Program. Fabrication of the STEP Turbine is nearing completion with all housings and pressure containing components in hand. This paper provides a detailed look at design intentions and limitations for the pressurized sections of the main pressure casing and the fabrication of key turbine components. Additional discussion is provided regarding postfabrication inspection and acceptance of the casing for use after issues with casing welds were identified late in the fabrication process.

Engineering↗
DOE OSTI2024

Design and Cooling Performance of Additively Manufactured Ceramic Turbine Vanes

Ceramic materials are of significant interest in aviation and power generation gas turbine engines due to their low density and ability to withstand high temperatures. Increased cycle thermal efficiency and higher specific power output is possible by incorporating ceramic components that enable high turbine inlet temperatures and lower required cooling airflow levels. However, ceramics can be difficult and costly to form into the complex shapes used in gas turbine components, often requiring specialized multi-step processes. Furthermore, ceramic components in the hottest areas of a gas turbine, such as vanes or blade shroud seals, will still likely require cooling which is challenging to implement in conventional ceramic manufacturing approaches. Therefore, this study presents a multidisciplinary approach that investigates the design, fabrication, and overall cooling effectiveness evaluation of additively manufactured (AM), polymer derived ceramic (PDC) turbine vanes. A thermo-mechanically optimized vane design was generated, ceramic additive manufacturing of the complex cooling configuration was developed, and quantification of the increase in overall cooling effectiveness was performed in a 1X scale, high-speed facility using infrared thermography. This study produced a PDC AM process, capable of printing complex internal cooling schemes in 1X scale turbine vanes. Furthermore, it was found that the optimized vane more than doubled the overall cooling effectiveness observed in the baseline design, which reasonably agreed with thermomechanical optimization model predictions. Additionally, the optimized ceramic vane outperformed an identical metal vane, in terms of area averaged cooling effectiveness, suggesting that the ceramic vane could operate at reduced coolant flowrates to achieve comparable levels of cooling performance.

Reynolds number↗