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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 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

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↗
DOE OSTI2025

Overall Cooling Effectiveness of Internally Cooled Additively Manufactured Blades

By utilizing additive manufacturing, novel internal cooling designs can be quickly and cheaply vetted to enhance blade cooling performance. This improvement allows for higher turbine inlet temperatures while reducing the amount of coolant needed, therefore increasing the overall efficiency of small industrial gas turbines.

additive manufacturing↗
DOE OSTI2025

Overall Cooling Effectiveness of Internally Cooled Additively Manufactured Blades

Power generation gas turbine blades must utilize highly effective cooling schemes to withstand moderate heat loads for long operating times. Prior work indicates that gas turbines in the 5-10 MW range primarily utilize internal cooling to prevent further increase of aerodynamic losses that result from film cooling, but few studies focus solely on internal cooling. In this study, three additively manufactured internal cooling designs were tested in the 50 percent span section of the National Experimental Turbine (NExT) blade: a baseline cooling design with pin-fin arrays and rib turbulators, a double wall design with impingement jets and serpentine channels, and an incremental impingement design. The designs were tested in a high-speed linear cascade at exit Reynolds numbers ranging from 700,000 to 1,400,000 at an exit Mach of 0.8. In addition, freestream turbulence and build angle effects on cooling performance were studied.

gas turbine blades↗
DOE OSTI2024

A One-dimensional Heat Transfer Model for a Cooled Airfoil in a Direct-fired Supercritical CO 2 Turbine

A one-dimensional (1-D) heat transfer model was developed to predict the performance of a cooled airfoil for a supercritical carbon dioxide (sCO 2 ) turbine. The model included the effects of film cooling effectiveness, thermal barrier coating thickness, and internal Nusselt number augmentation. Trends for overall cooling effectiveness versus heat load parameter were obtained for over twelve unique thermal management schemes. The study found that adding a thermal barrier coating was the most effective scheme for increasing the airfoil overall cooling effectiveness. Internal cooling technologies have diminishing returns as the heat transfer coefficient augmentation increases past a factor of five, however the sensitivity of overall cooling effectiveness to heat transfer augmentation scales by a factor of 1.3 when a thermal barrier coating is introduced. Film cooling is seen as a long-term research area which will be inevitably explored as direct sCO 2 systems develop a market presence. However, the model indicates that realizable film cooling effectiveness levels yield a smaller improvement in overall cooling effectiveness than a thermal barrier coating.

42 ENGINEERING↗
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↗
DOE OSTI2025

Simplified Model and Approach to Transform Infrared Surface Temperature to Film Effectiveness in a Conjugate Heat Transfer Experiment

In the pursuit of more efficient gas turbines, film cooling is a critical technology. This article describes a simplified engineering model based on a one-dimensional thermal resistance network. The model is used to relate film-cooling effectiveness and heat transfer augmentation to local overall cooling effectiveness in a conjugate flat plate experiment. Here, this article presents experimental proof-of-concept data to demonstrate the potential for this model. In contrast to previous approaches, neither the wall heat flux nor the adiabatic wall temperature is required to estimate the local film-cooling performance parameters. The model predicts surface temperatures that are within the experimental uncertainties over the range for which the model is trained and to within five percent when the model is extrapolated to higher coolant channel Reynolds numbers. This article is relevant to conjugate test rigs that can measure the hot-surface temperature distribution with and without film cooling. This information may also be relevant to designers as a method to approximate surface temperatures or used as an approximate heat transfer model for optimization studies.

advanced turbines↗
DOE OSTI2023

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. 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 flow rates to achieve comparable levels of cooling performance.

Fox, Andrew↗
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↗
DOE OSTI2023

Effects of Part-to-Part Flow Variations on Overall Effectiveness and Life of Rotating Turbine Blades

Abstract As firing temperatures in gas turbine engines continue to increase to achieve high efficiencies, components in the main gas path must be protected with cooling flows to ensure lifing targets are met. Manufacturing variations, however, influence the performance and life characteristics of components with the same nominal design. This study presents blade flow and overall cooling effectiveness measurements for nine true-scale, aero engine turbine blades with realistic manufacturing variations. Flow measurements were made through each blade at a fixed pressure ratio to determine flow variability between holes and between blades. Infrared thermography was used to capture spatially-resolved temperature measurements reported as overall effectiveness on the same nine blades under high-speed rotating conditions at the Steady Thermal Aero Research Turbine Laboratory. Thermal performance was correlated with blade flow performance indicating substantial blade-to-blade variations resulting from manufacturing differences. Measurements also indicated wide variations in cooling jet trajectories as well as overall cooling effectiveness. Finally, the observed blade-to-blade variations in effectiveness were scaled to engine conditions with lifing estimates showing some blades would be expected to last only half as long as others due to manufacturing variability.

Engineering↗
DOE OSTI2025

Simplified Model and Approach to Transform Infrared Surface Temperature to Film Effectiveness in a Conjugate Heat Transfer Experiment

This paper describes a simplified engineering model based on a one-dimensional thermal resistance network. The model is used to develop a new method to relate film cooling effectiveness and heat transfer augmentation to local overall cooling effectiveness in a conjugate flat plate experiment. This paper presents experimental proof-of-concept data to demonstrate the potential for this model. In contrast to previous approaches, neither the wall heat flux nor the adiabatic wall temperature is required to estimate the local film cooling performance parameters. The model predicts surface temperatures that are within the experimental uncertainties over the range for which the model is trained, and to within five percent when the model is extrapolated to higher coolant channel Reynolds numbers. This paper is relevant to conjugate test rigs that can measure the hot surface temperature distribution with and without film cooling. This information may also be relevant to designers as a method to approximate surface temperatures or used as an approximate heat transfer model for optimization studies.

advanced gas turbines↗
DOE OSTI2024

Integrated Turbine Component Cooling Designs Facilitated by Additive Manufacturing and Optimization

This research program involved the development of improved gas turbine cooling by optimizing the combined internal and film cooling configurations used for turbine blades and vanes. Improved cooling of turbine airfoils allows the gas turbines to be operated at higher temperatures which improves efficiency for gas turbine-based power generation. This also facilitates operation with hydrogen-based fuels which inherently generate higher operating temperatures. Designs of the new cooling configurations were based on the added geometric flexibility that is available when using metal additive manufacturing techniques. When making these designs, adjustments were made to account for imperfections occurring in the metal additive manufacturing process. New designs for film cooling holes were developed using computational adjoint gradient optimization techniques which generated a unique film cooling hole with 70% greater film cooling effectiveness compared to conventional shaped film cooling holes. A major factor in improving the film cooling effectiveness were small external protrusions on either side of the new hole which generated vortices that pushed coolant towards the surface and increased the lateral spreading of the coolant. Our studies also included optimization of film cooling holes that can be built with conventional manufacturing techniques and optimizing the internal coolant channels that supply coolant to the film cooling holes. Various internal coolant channel shapes were investigated and designs that maximized the cooling of the airfoil while minimizing pressure losses in the channel flows were identified. Testing and verification of the performance of the final configurations was done with a transonic wind tunnel facility which allowed testing at engine realistic high velocities. Final testing of the combined internal and film cooling configurations was done by incorporating the configurations in Penn State’s National Experimental Turbine (NExT) vane. These tests confirmed the enhanced overall cooling effectiveness provided by the new cooling configuration designs.

03 NATURAL GAS↗
DOE OSTI2026

Influence of Surface Aerosol Injection on Stratocumulus‐to‐Cumulus Transition: Cloud‐Surface Coupling and Background Aerosol Concentrations

The influence of surface aerosol injection on the stratocumulus‐to‐cumulus transition (SCT) is explored using large‐eddy simulations. We examine how cloud‐surface coupling (or the strength of the marine boundary layer (MBL) stratification that limits vertical turbulent mixing and convection) impacts the vertical transport of aerosols, and how injected aerosols influence cloud properties and associated cloud radiative effects during the SCT. By injecting aerosols at different stages of the SCT, noting that cloud is more decoupled from the surface over time due to entrainment warming, we find that cloud‐surface coupling significantly affects aerosol vertical transport. However, injection timing (before drizzle if any) does not notably affect the SCT and the efficiency of marine cloud brightening, because aerosol number concentrations due to injections at different times rapidly converge before the transition onset. By varying the background aerosol concentration, we find that injected aerosols can significantly extend the persistence of stratocumulus decks by suppressing precipitation in clean environments but have little impact on stratocumulus breakup with higher background aerosol concentrations due to saturated aerosol effects. In clean MBLs, the SCT‐delay‐induced increase in cloud fraction dominates the overall cooling effects in response to aerosols, followed by Twomey effects. These cooling effects are slightly offset by decreased liquid water path (LWP) due to entrainment drying. In polluted MBLs, the Twomey effect is more dominant, followed by cloud fraction adjustments, and these coolings are also partly offset by LWP adjustments. All the simulations are made in relatively small domains in which injected aerosols are homogenized over a short time scale.

Zhang, Haipeng [Univ. of Maryland, College Park, M↗
DOE OSTI2024

The correlation between Arctic sea ice, cloud phase and radiation using A-Train satellites

Abstract. Climate warming has a stronger impact on Arctic climate and sea ice cover (SIC) decline than previously thought. Better understanding and characterization of the relationship between sea ice and clouds and the implications for surface radiation is key to improving our confidence in Arctic climate projections. Here we analyze the relationship between sea ice, cloud phase and surface radiation over the Arctic, defined as north of 60° N, using active- and passive-sensor satellite observations from three different datasets. We find that all datasets agree on the climatology of and seasonal variability in total and liquid-bearing (liquid and mixed-phase) cloud covers. Similarly, our results show a robust relationship between decreased SIC and increased liquid-bearing clouds in the lowest levels (below 3 km) for all seasons (strongest in winter) but summer, while increased SIC and ice clouds are positively correlated in two of the three datasets. A refined map correlation analysis indicates that the relationship between SIC and liquid-bearing clouds can change sign over the Bering, Barents and Laptev seas, likely because of intrusions of warm air from low latitudes during winter and spring. Finally, the increase in liquid clouds resulting from decreasing SIC is associated with enhanced radiative cooling at the surface. Our findings indicate that the newly formed liquid clouds reflect more shortwave (SW) radiation back to space compared to the surface, generating a cooling effect of the surface, while their downward longwave (LW) radiation is similar to the upward LW surface emission, which has a negligible radiative impact on the surface. This overall cooling effect should contribute to dampening future Arctic surface warming as SIC continues to decline.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

Development of Additive Manufacturing for Ceramic Matrix Composite Vanes

This report discusses the development of additive manufacturing for polymer-derived ceramic materials to create novel cooled gas turbine airfoils made from ceramics. Gas turbine engines have extremely high temperatures in the hot section of the engine that exceed the melting point of nickel superalloy materials that the engine is made from. Advanced cooling technologies have been developed over decades for metallic parts. Ceramic materials have higher temperature capabilities than superalloys, but are difficult to shape in the complex designs used in modern turbines. Several thrusts were investigated during the project, including development of higher material strength resins, improvement of ultraviolet (UV) photopolymerization and post-processing techniques to increase survivability of ceramic parts, thermomechanical modeling of novel ceramic airfoil designs for higher cooling effectiveness, and experimental validation of the modeling and manufacturing in a turbine vane test facility at nondimensional conditions that are relevant to modern gas turbines. Some major findings of the work include a significant increase in ceramic survivability during pyrolysis (a high temperature process that converts the organic material to a ceramic) by adjusting the composition ratios of the resins, as well as a tolulene soak after printing to remove unreacted polymer material. Thermomechanical optimization of the internal cooling structure indicated that a high density pin fin array would enable an 80% increase in overall cooling effectiveness relative to a baseline geometry, which was later verified during experimental testing in a high speed linear cascade. Ceramic vanes were tested at Mach numbers of up to 0.9 which is relevant to modern gas turbines. High temperature capability of the ceramic vanes was not tested in this work.

36 MATERIALS SCIENCE↗
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↗
DOE OSTI2021

Experimental Investigation of Innovative Cooling Schemes on an Additively Manufactured Engine Scale Turbine Nozzle Guide Vane

This study includes the design, validation, and fabrication via direct metal laser sintering (DMLS) of a gas turbine nozzle guide vanes (NGV) that incorporates three innovative cooling schemes specifically enabled by additive manufacturing. The novel NGV design is the culmination of an extensive research and development effort over a period of 4 years that included low- and high-speed cascade testing coupled with unsteady computational fluid dynamics for numerous candidate innovative cooling architectures. The final vane design (SJ-vane) consists of sweeping jet (SJ) film cooling holes on the suction surface (SS), sweeping jet impingement holes at the leading edge and double-wall partial length triangular pin-fin with impinging jet at the trailing edge. For comparison purposes, a second DMLS enabled vane (777-vane) was designed and fabricated with prototypical cooling circuits to serve as a baseline. This vane consists of a shaped film cooling holes on the suction surface, circular impingement holes at the leading edge, and full-length cylindrical pin-fins at the trailing edge. Experiments with the two DMLS enabled vanes were performed at the Ohio State University Turbine Reacting Flow Rig (TuRFR) at engine-relevant temperature (1375 K) and Mach number conditions. Infrared (IR) thermography was utilized to measure the wall temperature of the pressure and suction surface at several coolant mass flowrates to estimate the overall cooling effectiveness (ϕ). Results showed improved cooling performance for the advanced cooling schemes (sweeping jet film cooling, impingement cooling, and triangular pin-fin cooling) compared with the baseline cooling schemes.

Engineering↗
DOE OSTI2024

Computational Study of Additively Manufactured Internally Cooled Airfoils for Industrial Gas Turbine Applications

Internal cooling features such as pin-fins, impingement jets, and rib-turbulators are necessary to keep turbine components cool, but if sufficiently advanced can potentially also eliminate the need for film cooling on turbine blades particularly in industrial gas turbines where temperatures are not extreme. Furthermore, by leveraging additive manufacturing, other advanced designs such as lattice and incremental impingement configurations are possible and have recently been experimentally tested. While the performance of such configurations has been quantified through means of overall cooling effectiveness, it is not as clear why certain designs were better than others, or what the mechanisms were behind the observed external cooling patterns. The purpose of this study was to computationally analyze different advanced turbine blade internal cooling designs previously tested by the National Energy Technology Laboratory.

CFD↗
DOE OSTI2024

Effects of Downstream Vortex Generators on Film Cooling a Flat Plate Fed by Crossflow

Counter-rotating vortices, formed by the interaction of film-cooling jets and the hot gas flow, adversely affect the performance of conventional film-cooling designs. Downstream vortex generators have been shown to improve cooling effectiveness by mitigating the effects of the counter-rotating vortices and by deflecting the cooling jet laterally. In this study, computational and experimental methods were used to examine how cylindrical film-cooling holes (D = 3.2 mm, L/D = 6, p/D = 3, α = 30 deg) with and without downstream vortex generators perform when the coolant supply channel is perpendicular to the direction of the hot gas. For this study, the hot gas had a temperature of 650 K and an average Mach number of 0.23. Here, the hot-gas-to-coolant temperature ratio was 1.9, and two blowing ratios (0.75 and 1.0) were studied. Results from the computational fluid dynamics study show how crossflow affects the interaction between the film-cooling jet and hot gas flow with and without downstream vortex generators. The experimental measurements were based on infrared thermography in a conjugate heat transfer environment. Results were obtained for film-cooling performance in terms of overall effectiveness, film effectiveness, and local heat transfer coefficients. The downstream vortex generators can increase the laterally averaged effectiveness by a factor of 1.5 relative to cylindrical holes, but this higher performance is restricted to low crossflow velocities and higher blowing ratios.

17 WIND ENERGY↗