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The goal of the present work was to identify and implement modifications to a density-based unstructured RANS CFD algorithm, as typically used in turbomachinery flows (represented here via the RoIIs-Royce 'Hydra' code), for application to Iow Mach number gas-turbine combustor flows. The basic algorithm was modified to make it suitable for combustor relevant problems. Fixed velocity and centreline boundary conditions were added using a characteristic based method. Conserved scalar mean and variance transport equations were introduced to predict scalar mixing in reacting flows. Finally, a flarnelet thermochemistry model for turbulent non-premixed combustion with an assumed shape pdf for turbulence-chemistry interaction was incorporated. A method was identified whereby the temperature/ density provided by the combustion model was coupled directly back into the momentum equations rather than from the energy equation. Three different test cases were used to validate the numerical capabilities of the modified code, for isothermal and reacting flows on different grid types. The first case was the jet in confined cross flow associated with combustor liner-dilution jetcore flow interaction. The second was the swirling flow through a multi-stream swirler. These cases represent the main aerodynamic features of combustor primary zones. The third case was a methane-fueled coaxial jet combustor to assess the combustion model implementation. This study revealed that, via appropriate modifications, an unstructured density-based approach can be utilised to simulate combustor flows. It also demonstrated that unstructured meshes employing nonhexahedral elements were inefficient at accurate capture of flow processes in regions combining rapid mixing and strong convection at angles to cell edges. The final version of the algorithm demonstrated that low Mach RANS reacting flow simulations, commonly performed using a pressure-based approach, can successfully be reproduced using a density-based approach.

Unsteady three-dimensional flow phenomena have major effects on the aerodynamic performance of, and heat transfer to, gas-turbine blading. Investigation of the mechanisms associated with these phenomena requires an experimental facility that is capable of simulating a gas turbine, but at lower levels of temperature and pressure to allow conventional measurement techniques. This thesis reports on the design, development and commissioning of a new experimental facility that models these unsteady three-dimensional flow phenomena. The new facility, which consists of a 62%-size, high-pressure gas-turbine stage mounted in a transient wind tunnel, simulates the turbine design point of a full-stage turbine. The thesis describes the aerodynamic and mechanical design of the new facility, a rigorous stress analysis of the facility’s rotating system and the three-stage commissioning of the facility. The thesis concludes with an assessment of the turbine stage performance.