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89 records · Page 5

Energy efficient engine, high pressure turbine thermal barrier coating. Support technology report

This report describes the work performed on a thermal barrier coating support technology task of the Energy Efficient Engine Component Development Program. A thermal barrier coating (TBC) system consisting of a Ni-Cr-Al-Y bond cost layer and ZrO2-Y2O3 ceramic layer was selected from eight candidate coating systems on the basis of laboratory tests. The selection was based on coating microstructure, crystallographic phase composition, tensile bond and bend test results, erosion and impact test results, furnace exposure, thermal cycle, and high velocity dynamic oxidation test results. Procedures were developed for applying the selected TBC to CF6-50, high pressure turbine blades and vanes. Coated HPT components were tested in three kinds of tests. Stage 1 blades were tested in a cascade cyclic test rig, Stage 2 blades were component high cycle fatigue tested to qualify thermal barrier coated blades for engine testing, and Stage 2 blades and Stage 1 and 2 vanes were run in factory engine tests. After completion of the 1000 cycle engine test, the TBC on the blades was in excellent condition over all of the platform and airfoil except at the leading edge above midspan on the suction side of the airfoil. The coating damage appeared to be caused by particle impingement; adjacent blades without TBC also showed evidence of particle impingement.

Duderstadt, E. C.↗

Design optimization of transonic airfoils

Numerical optimization procedures were considered for the design of airfoils in transonic flow based on the transonic small disturbance (TSD) and Euler equations. A sequential approximation optimization technique was implemented with an accurate approximation of the wave drag based on the Nixon's coordinate straining approach. A modification of the Euler surface boundary conditions was implemented in order to efficiently compute design sensitivities without remeshing the grid. Two effective design procedures producing converged designs in approximately 10 global iterations were developed: interchanging the role of the objective function and constraint and the direct lift maximization with move limits which were fixed absolute values of the design variables.

Joh, C.-Y.↗

A computational transonic flutter boundary tracking procedure

An automated flutter boundary tracking procedure is presented for the efficient calculation of transonic flutter boundaries. The new procedure uses aeroelastic responses to march along the boundary by taking steps in speed and Mach number, thereby reducing the number of response calculations previously required to determine a transonic flutter boundary. The tracking procedure reduces computational costs since only two response calculations are required per Mach number and provides a complete boundary in a single job submission. Flutter boundary results are presented for a typical airfoil section oscillating with pitch and plunge degrees of freedom. These transonic flutter boundaries are in good agreement with 'exact' boundaries calculated using the conventional time-marching method. The tracking procedure was also extended to include static aeroelastic twist as a simulation of the static deformation of a wing and thus contains all of the essential features that are required to apply it to practical three-dimensional cases. Application of the procedure is also made to flutter boundaries as a function of structural parameters, the capability of which is useful as a design tool.

Gallman, J. W.↗

A new method for designing shock-free transonic configurations

A new method for the design of shock-free supercritical airfoils, wings, and three-dimensional configurations is described. Results illustrating this procedure in two and three dimensions are given. They include modifications to part of the upper surface of an NACA 64A410 airfoil that will maintain shock-free flow over a range of Mach numbers for a fixed lift coefficient, and the modifications required on part of the upper surface of a swept wing with an NACA 64A410 root section to achieve shock-free flow. While the results are given for inviscid flow, the same procedures can be employed iteratively with a boundary layer calculation in order to achieve shock-free viscous designs. With a shock-free pressure field the boundary layer calculation will be reliable and not complicated by the difficulties of shock-wave boundary-layer interaction.

Sobieczky, H.↗

Computed unsteady flows of airfoils at high incidence

The flow over an airfoil at an angle of attack above the static stall angle would ordinarily be massively separated. Under dynamic conditions, the onset of stall can be delayed to an angle, depending on the type of unsteadiness, much higher than that for static stall. The stall onset mechanisms under dynamic conditions are unclear. Due to extreme difficulties involved, experimental investigations, so far, have provided insufficient information about the flow field for the identification of the onset mechanisms. A course of classical boundary layer analysis augmented with numerical experiments and measured data is chosen here instead, with the hope that the identification of onset mechanisms can be more systematic and quantitative.

Fung, K.-Y.↗

Gust Acoustic Response of a Single Airfoil Using the Space-Time CE/SE Method

A 2D parallel Euler code based on the space-time conservation element and solution element (CE/SE) method is validated by solving the benchmark problem I in Category 3 of the Third CAA Workshop. This problem concerns the acoustic field generated by the interaction of a convected harmonic vortical gust with a single airfoil. Three gust frequencies, two gust configurations, and three airfoil geometries are considered. Numerical results at both near and far fields are presented and compared with the analytical solutions, a frequency-domain solver GUST3D solutions, and a time-domain high-order Discontinuous Spectral Element Method (DSEM) solutions. It is shown that the CE/SE solutions agree well with the GUST3D solution for the lowest frequency, while there are discrepancies between CE/SE and GUST3D solutions for higher frequencies. However, the CE/SE solution is in good agreement with the DSEM solution for these higher frequencies. It demonstrates that the CE/SE method can produce accurate results of CAA problems involving complex geometries by using unstructured meshes.

Scott, James↗

RANS and DES Computations for a Wing with Ice Accretion

A computational investigation was performed to assess the effectiveness of Detached Eddy Simulation (DES) as a tool for predicting icing effects. The AVUS code, a public domain flow solver, was employed to compute solutions for an iced wing configuration using DES and steady Reynolds Averaged Navier-Stokes (RANS) equation methodologies. The wing section considered here was a business jet airfoil (GLC305) with a 22.5-minute glaze ice accretion (944-ice shape). The section was extruded to form a rectangular planform. The model was mounted between two walls so no tip effects were considered. The numerical results were validated by comparison with experimental data for the same configuration. The time-averaged DES computations showed some improvement in lift and drag results near stall when compared to steady RANS results. However, comparisons of the flow field details did not show the level of agreement suggested by the integrated quantities. More validation is needed to determine what role DES can play as part of an overall icing effects prediction strategy.

Mogili, P.↗

Thermal barrier coatings issues in advanced land-based gas turbines

The Department of Energy's Advanced Turbine System (ATS) program is aimed at forecasting the development of a new generation of land-based gas turbine systems with overall efficiencies significantly beyond those of current state-of-the-art machines, as well as greatly increased times between inspection and refurbishment, improved environmental impact, and decreased cost. The proposed duty cycle of ATS turbines will require the use of different criteria in the design of the materials for the critical hot gas path components. In particular, thermal barrier coatings will be an essential feature of the hot gas path components in these machines. While such coatings are routinely used in high-performance aircraft engines and are becoming established in land-based turbines, the requirements of the ATS turbine application are sufficiently different that significant improvements in thermal barrier coating technology will be necessary. In particular, it appears that thermal barrier coatings will have to function on all airfoil sections of the first stage vanes and blades to provide the significant temperature reduction required. In contrast, such coatings applied to the blades and vances of advanced aircraft engines are intended primarily to reduce air cooling requirements and extend component lifetime; failure of those coatings can be tolerated without jeopardizing mechanical or corrosion performance. A major difference is that in ATS turbines these components will be totally reliant on thermal barrier coatings which will, therefore, need to be highly reliable even over the leading edges of first stage blades. Obviously, the ATS program provides a very challenging opportunity for TBC's, and involves some significant opportunities to extend this technology.

Parks, W. P.↗

The effects of compressibility on dynamic stall

In this paper, typical computational predictions and experimental measurements of compressible flow past an airfoil at dynamic stall conditions are studied and compared to develop an insight into the effect of compressibility on dynamic stall. The dependency of the critical Mach number on airfoil leading edge curvature, camber, and angle of attack is investigated. Evidence is presented to show that a local region of supersonic flow occurs on an oscillating airfoil, even for a freestream Mach number as low as 0.2, if the boundary layer remains attached and the angle of attack is sufficiently high; that a shock terminates this local supersonic bubble; and that the vorticity that this shock generates grows rapidly and becomes very unstable as the angle of attack increases beyond the value at which the maximum local flow speed first exceeds the speed of sound. It is suggested that these shock-induced effects compete with the dynamic viscous effects occurring in the boundary layer in determining the onset of separation, which can lead to premature dynamic stall and can significantly reduce the maximum dynamic lift that can otherwise be obtained.

Fung, K.-Y.↗

Investigation of forced unsteady separated flows using velocity-vorticity form of Navier-Stokes equations

The phenomenon of forced unsteady separation and eruption of boundary-layer vorticity is a highly-complex, high-Reynolds number flow phenomenon, which abruptly leads to the formation of a dynamic stall vortex as demonstrated earlier by the authors for a NACA 0015 airfoil undergoing constant rate pitch-up motion. This, as well as the results of other researchers, have convincingly demonstrated a complex vortical structure within the state of unsteady separation prior to the evolution of dynamic stall. This phenomenon of vortex eruption, although observed in studying dynamic stall phenomena, is also associated with transition from laminar to turbulence flow and its generic nature has been stressed by many researchers including the present investigators. An unsteady Navier-Stokes (NS) analysis is developed for arbitrarily maneuvering bodies using velocity-vorticity variables; this formulation is nearly form-invariant under a generalized non-inertial coordinate transformation. A fully-implicit uniformly second-order accurate method is used, with the nonlinear convective terms approximated using a biased third-order upwind differencing scheme to be able to simulate higher-Re flows. No explicit artificial dissipation is added. The numerical method is fully vectorized and currently achieves a computational index of 7 micro-seconds per time step per mesh point, using a single processor on a CRAY Y-MP. The simulation results show that the energetic free shear from the leading edge is responsible for the wall viscous layer to abruptly erupt near the center of the counterclockwise rotating eddy in the unsteady boundary layer. Primary, secondary, tertiary and quaternary vortices have been observed before the dynamic stall vortex evolves and gathers its maximum strength. This study will discuss the simulation results of Reynolds number up to Re = 45,000 and will also discuss the efforts of initial acceleration in a specific maneuver, on the evolution of the stall vortex.

Ghia, K. N.↗

A Comparative Study Using CFD to Predict Iced Airfoil Aerodynamics

WIND, Fluent, and PowerFLOW were used to predict the lift, drag, and moment coefficients of a business-jet airfoil with a rime ice (rough and jagged, but no protruding horns) and with a glaze ice (rough and jagged end has two or more protruding horns) for angles of attack from zero to and after stall. The performance of the following turbulence models were examined by comparing predictions with available experimental data. Spalart-Allmaras (S-A), RNG k-epsilon, shear-stress transport, v(sup 2)-f, and a differential Reynolds stress model with and without non-equilibrium wall functions. For steady RANS simulations, WIND and FLUENT were found to give nearly identical results if the grid about the iced airfoil, the turbulence model, and the order of accuracy of the numerical schemes used are the same. The use of wall functions was found to be acceptable for the rime ice configuration and the flow conditions examined. For rime ice, the S-A model was found to predict accurately until near the stall angle. For glaze ice, the CFD predictions were much less satisfactory for all turbulence models and codes investigated because of the large separated region produced by the horns. For unsteady RANS, WIND and FLUENT did not provide better results. PowerFLOW, based on the Lattice Boltzmann method, gave excellent results for the lift coefficient at and near stall for the rime ice, where the flow is inherently unsteady.

Chi, x.↗

Trailing edge noise from hovering rotors

A method has been developed to predict the high frequency broadband noise due to the interaction of convecting turbulent eddies with the trailing edges of a hovering rotor. The trailing edge noise from each blade was modeled as point dipole noise with spanwise loading corrections. This point dipole approximation was checked by applying the concept to a stationary airfoil in a moving medium with excellent results. In order to estimate the strength of the point dipole, the trailing edge noise theory of Amiet was used. The method was applied specifically to blade boundary layer turbulence and compared to incident atmospheric turbulence noise. The results indicate that the relative importance of these two mechanisms is related to the magnitudes of the intensity and of the length scales of the inflow and boundary layer turbulence. The results tend to fall below some available experimental data indicating that in those experiments other broadband noise sources were stronger than boundary layer-trailing edge noise. The approach which was developed is also applicable to other blade-turbulence interaction mechanisms such as local stall and tip noise.

Kim, Y. N.↗

Transonic swept wings studied by the lifting-line theory

Transonic swept wings are analyzed as a lifting-line problem under a small-disturbance approximation. Basic concepts and principal results of the asymptotic theory are discussed. The study focuses on straight oblique wings and V-shaped swept wings, of which the local centerline curvature can be equated to zero. The three-dimensional (3-D) perturbation of the nonlinear component flow admits a similarity flow structure but requires that all wing sections are generated from a single airfoil profile; the reduced 2-D problems in this case are solved only once for all span stations. Examples of solutions involving high subcritical and slightly supercritical component flows are demonstrated and compared with surface pressure data from 3-D computer codes based on the full-potential equation (FLO 22). Except in the neighborhood of leading edges, where the small-disturbance assumption breaks down, and in the vicinities of wing tips and the symmetry plane, where neither the theory nor the 3-D codes may claim full validity, reasonable agreement is consistently found. The explicit results from the upwash analysis, along with the similarity flow structure, provides a rational approach to the control of 3-D effects in transonic aerodynamic design studies.

Cheng, H. K.↗

Flow distributions and discharge coefficient effects for jet array impingement with initial crossflow

To model the impingement cooled mid-chord region of gas turbine airfoils in cases where an initial crossflow is present, the paper presents experimentally determined flow distributions for jet arrays with ten spanwise rows of holes, which range from uniform to highly nonuniform. The jet flow after impingement is constrained to exit in a single direction along the channel formed by the jet orifice plate and the impingement surface. The streamwise distributions and crossflow velocities are presented for ratios of the initial crossflow rate to the total jet flow rate ranging from zero to unity. For crossflow to jet velocity ratios greater than a value somewhat less than unity, jet orifice discharge coefficients do not remain constant, but decrease significantly, showing a secondary dependence on z/d, where z is the channel height and d is the jet hole diameter.

Florschuetz, L. W.↗

Investigation of CAST-10-2/DOA 2 airfoil in NAE high Reynolds number two-dimensional test facility

A common airfoil model with the CAST 10-2/DOA-2 profile and 228 mm (9 inches) chord length was tested. The tests performed in NAE covered the Mach numbers from 0.3 to 0.8 and Reynolds numbers from 10 to 30 million. The model was tested with transition free and with transition fixed at 5 percent chord for both the upper and the lower surfaces. The data obtained were analyzed for the effects of Reynolds number, transition fixing and Mach number. The role of the boundary layer on the displacement effect, the interaction with the shock wave and the trailing edge separation are examined. The results are summarized as follows: (1) the airfoil performance depends strongly on Reynolds number and transition fixing; (2) with transition fixed, the aerodynamic quantities such as lift, pitching moment and drag show a monotonic variation with Reynolds number; (3) with transition free, the aerodynamic quantities vary less regularly with Reynolds number and a slight parametric dependency is shown. The weak dependency is due to the compensatory effect of the forward shift of the transition position and the thinning of the turbulent boundary layer as Reynolds number increases; (4) the shock Mach number and the shock position are weakly dependent on Reynolds number; and (5) the long extent of the laminar boundary layer at transonic speeds reduces the drag appreciably at low Reynolds numbers. The drag bucket around the design Mach number can be observed below Reynolds number 15 million.

Chan, Y. Y.↗

Large-Vortex Capture by a Wing at Very High Angles of Attack

In generating the lift on a wing, the static stall is a severe barrier. As the angle of attack, alpha, increases to the stall angle, alpha(sub stall) the flow separation point on the upper surface of the wing moves to the leading edge, so that on a two-dimensional airfoil or a large-aspect-ratio wing, the lift abruptly drops to a very low level. Therefore, the first generation of aeronautical flow type, i.e., the attached steady flow, has been limited to alpha less than alpha(sub stall). Owing to the obvious importance in applications, therefore, a great effort has been made in the past two decades to enlarge the range of usable angles of attack by various flow controls for a large-aspect-ratio wing. Basically, relevant works fall into two categories. The first category is usually refereed to as separation control, which concentrates on partially separated flow at alpha less than alpha(sub stall). Since the first experimental study of Collins and Zelenevitz, there has been ample literature showing that a partially separated flow can be turned to almost fully attached by flow controls, so that the lift is recovered and the stall is delayed (for a recent work see Seifert et al.). It has been well established that, in this category, unsteady controls are much more effective than steady ones and can be realized at a very low power-input level (Wu et al.; Seifert et al.). The second and more ambitious category of relevant efforts is the post-stall lift enhancement. Its possibility roots at the existence of a second lift peak at a very high angle of attack. In fact, As alpha further increases from alpha(sub stall), the completely separated flow develops and gradually becomes a bluff-body flow. This flow gives a normal force to the airfoil with a lift component, which reaches a peak at a maximum utilizable angle of attack, alpha(sub m) approx.= 40 deg. This second peak is of the same level as the first lift peak at alpha(sub stall). Meanwhile, the drag is also quickly increased (e.g., Fage and Johansen ; Critzos et al.). Figure 1 shows a typical experimental lift and drag coefficients of NACA-0012 airfoil in this whole range of angle of attack. Obviously, without overcoming the lift crisis at alpha(sub stall) the second lift peak is completely useless. Thus, the ultimate goal of post-stall lift enhancement is to fill the lift valley after stall by flow controls, so that a wing and/or flap can work at the whole range of 0 deg less than alpha less than alpha(sub m). Relevant early experimental studies have been extensively reviewed by Wu et al., who concluded that, first, similar to the leading-edge vortex on a slender wing, the lift enhancement on a large-aspect-ratio wing should be the result of capturing a vortex on the upper surface of the wing; and, second, using steady controls cannot reach the goal, and one must rely on unsteady controls with low-level power input as well. Wu et al. also conjectured that the underlying physics of post-stall lift enhancement by unsteady controls consists of a chain of mechanisms: vortex layer instability - receptivity resonance - nonlinear streaming.

Wu, J. M.↗

Numerical studies of porous airfoils in transonic flow

A numerical tool is constructed to examine the effects of a porous surface on transonic airfoil performance and to help understand the flow structure of passive shockwave/boundary layer interactions. The porous region is located near the shock with a cavity underneath it. This study is composed of two parts. Solved in the first part, with an inviscid-flow approach, is the transonic full-potential equation associated with transpiration boundary conditions which are obtained from porosity modeling. The numerical results indicate that a porous airfoil has a wave drag lower than that of a solid airfoil. The observed lambda-shock structure in the wind-tunnel testing can be predicted. Furthermore, the lift could be increased with an appropriate porosity distribution. In the second part of this work, the modified version of either an interactive boundary layer (IBL) algorithm or a thin-layer Navier-Stokes (TLNS) algorithm is used to study the outer flow, while a stream-function formulation is used to model the inner flow in the shallow cavity. The coupling procedure at the porous surface is based on Darcy's law and the assumption of a constant total pressure in the cavity. In addition, a modified Baldwin-Lomax turbulence model is used to describe the transpired turbulent boundary layer in the TLNS approach, while the Cebeci turbulence model is used in the IBL approach. According to the present analysis, a porous surface can reduce the wave drag appreciably, but can also increase the viscous losses. As has been observed experimentally, the numerical results indicate that the total drag is reduced at higher Mach numbers and increased at lower Mach numbers when the angles of attack are small. Furthermore, the streamline pattern of passive shock/boundary layer interaction are revealed.

Chow, C. Y.↗