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This thesis reports on work undertaken to understand the effects, due to wear, on the performance of abradable honeycomb labyrinth seals. The phenomena studied are aerodynamic in nature and include compressible flow, turbulent flow, recirculation and separation at a range of pressure ratios from 1.20 up to 3.50. Four primary methods of investigation were used: experimental, numerical using CFD, numerical using theoretical derivations and numerical using established labyrinth seal specific computer codes. Effects of seal clearance, pressure ratio and tooth to groove location have been investigated with overall performance and inter-seal pressure distribution recorded experimentally and numerically for comparison. Worn experimental results, when compared to their unworn equivalent, recorded large increases in mass flow of up to 50% when the labyrinth teeth are located centrally in the groove. Significant performance enhancements were achieved through offsetting the teeth with respect to the groove, particularly in an upstream sense. There was a marked deterioration with the labyrinth teeth located at the groove exit. Inter-seal pressure distributions showed that the first and final teeth did most of the work achieving significantly larger pressure drops which goes against current seal understanding of increasing pressure drop through the seal. Numerical work was undertaken to further investigate these effects. However, due to the complex 3-D geometry of an abradable honeycomb labyrinth seal a 2-D simplification technique was developed to speed up the investigative process. Using this technique CFD was found capable of replicating the experimental data regarding overall seal performance and inter-seal pressure distributions. The pressure on the final tooth proved to be the hardest experimental data to recreate using CFD, particularly at high pressure ratios when shocks are likely to form. Further numerical work was undertaken using computer codes and theoretical derivations. This work proved that the understanding of the seal loss coefficients used by both methods was not adequate for the current study with the experimental data recreated least successfully. Suggestions are given for enhancement of seal design, including axial location and seal computational routines, which will limit the impact of a 1.5% increase in operational cost that is likely to accrue from seal deterioration.

This thesis investigates numerically the phenomenon of flutter in labyrinth seals. Computational fluid dynamics (CFD) methods are used to predict the fluid forces produced in the labyrinth when one of the seal members is vibrating in its natural mode. The geometry of the seal, the vibrational characteristics and the flow characteristics are varied to determine their influence on the aeroelastic stability. The CFD results are used to develop a bulk-flow model for labyrinth seal flutter analysis. An aeroelastic design procedure for labyrinth seal is pro-posed.

Improvements upon current gas turbine sealing technology performance are essential for decreasing specific fuel consumption to meet stringent future efficiency targets. The clearances between rotating and static components of a gas turbine, which need to be sealed, vary over a flight cycle. Hence, a seal which can passively maintain an optimum clearance, whilst preventing contact between itself and the rotor, is extremely desirable. Various configurations of a Rolls Royce (RR) seal concept, the Large Axial Movement Face Seal (LAMFS), use static pressure forces to locate face seals. Prototypes were tested experimentally at the Osney Thermofluids Laboratory, Oxford. Firstly a proof-of concept rig (simulating a 2-D seal cross-section) manufactured by RR was re-commissioned. The simplest configuration using parallel seal faces induced an unstable seal housing behaviour. The author used this result, CFD, and analytical methods to improve the design and provide a self-centring ability. A fully annular test rig of this new seal concept was then manufactured to simulate a 3D engine representative seal. The full annulus eliminated leakage paths unavoidable in the simpler rig. A parametric program of experiments was designed to identify geometries and conditions which favoured best-practice design. The new seal design is in the process of being patented by Rolls Royce. A 'fluidic' seal was also investigated, showing very promising results. A test rig was manufactured so that a row of jets could be directed across a leakage cross-flow. An experimental program identified parameters which could achieve a combined lower leakage mass flow rate compared with the original leakage. Influence of jet spanwise spacing, injection angle, jet to mainstream pressure ratio, mainstream pressure difference and channel height were analysed. It is hoped this thesis can be used as a tool to further improve these seal concepts from the parametric trends which were identified experimentally.

L'impact des émissions fugitives sur l'environnement est un enjeu capital pour les industries. Ainsi, de nombreuses réglementations et normes sont établies afin de prévenir des risques et limiter leurs impacts. L'une des sources majeures de ces émissions provient de la robinetterie industrielle. Dans ce domaine, l'un des systèmes les plus communs est le presse-garniture. Dans le secteur de l'Energie, l'étanchéité peut être garantie sur les éléments mobiles par un empilement de bagues en Graphite Expansé Matricé (GEM); matériau relativement souple, plébiscité pour ses caractéristiques et ayant une structure macroscopique particulière. Ces travaux de thèse s'intéressent à la compréhension du comportement mécanique complexe des solutions d'étanchéité de type GEM. L'objectif est de déterminer le comportement mécanique de ces garnitures afin de prédire leur étanchéité. Dans le but de caractériser ce comportement, diverses campagnes d'essais sont menées sur des joints en situation. Ainsi, sur la base d'un montage existant et d'un dispositif développé spécifiquement pour cette étude, la caractérisation de ce type de joints est effectuée via des essais de compression charge-décharge et cyclique. La base de données qui en résulte permet le développement d'un modèle numérique apte à décrire le comportement complexe de ces systèmes presse-garnitures. Ce modèle phénoménologique de type Hyperélasto-Hystérésis (HH) correspond à une loi additive en contrainte avec une contribution hyperélastique et une contribution hystérétique. La comparaison des réponses expérimentales et numériques du joint, dans le cadre de l'étude d'un seul joint mais également pour des empilements, est discutée. / The impact of fugitive emissions leakage rate on the environment is an essential issue for industries. Therefore, many regulations and standards are created to prevent risks and to limit their impacts. One of these major sources of fugitive emissions comes from industrial valves. In the Valve Industrie, the tightness of stem are often ensured by stuffing box seal. In the energy sector, the tightness could be ensure with compression packing which is manufactured in exfoliated graphite; which is a relatively flexible material, endorsed for its characteristics and having a particular macroscopic structure. The aim of this study is to improve the knowledge of the complex mechanical behaviour of compression packing in exfoliated graphite. The aim is to determinate the mechanical behaviour of these packings in order to predict their tightness. To characterize this behaviour, various test campaigns are conducted on seals in situation. Thus, based on an existing apparatus and a device developed specifically for this study, the characterization of this kind of packing is performed through loading-unloading and cyclic compression tests. A numerical model which is able to describe a complexe mechanical behaviour of compression packing, is performed thanks to resulting database. This Hyperelasto-Hysteresis phenomenological model corresponds to an additive decomposition in stress with an hyperelastic contribution and an hysteretic contribution. The comparison of the experimental and numerical responses of the seal, as part of the study a single seal but also of a packing, is discussed.

La grande diversité des applications, dans tous les domaines industriels, des plus simples aux plus complexes, que ce soit pour un usage quotidienne ou pour des applications high-tech, nécessite la conception continue de systèmes d'étanchéité de plus en plus performants. Les vérins pneumatiques sont des éléments fondamentaux de l'automatisation dans des domaines industriels très variés : les dispositifs de levage, la robotique, l'aérospatial, les systèmes respiratoire, etc. Cependant, un dysfonctionnement d'étanchéité conduit à des performances plus faibles et même à des disfonctionnements. Inversement, une meilleure connaissance des phénomènes aux interfaces, permettra l’amélioration du rendement, la prolongation de la durée de vie et de la fiabilité des différentes applications pneumatiques.Ce travail de thèse est focalisé sur l'étude expérimentale et numérique des systèmes d'étanchéité par joints pneumatiques. Un banc d'essais modulable a été conçu et réalisé pour permettre l'investigation expérimentale de différents types de joints pneumatiques, pour une large gamme de conditions de fonctionnement, en termes de vitesse linéaire, pression pneumatique et solutions constructives. Il permet principalement de caractériser le frottement des joints mais aussi la visualisation des phénomènes physiques au niveau de la zone d'étanchéité et de son environnement.En parallèle, un modèle théorique ElastoHydroDynamique, incluant la prise en compte des conditions de lubrification mixte et le comportement rhéologique non-newtonien de lubrifiant (graisse) a été développé. Il est basé sur le couplage d'un logiciel de calcul non-linéaire (permettant la prise en compte du comportement mécanique hyperélastique des joints) et un modèle d'écoulement en film mince. Les comparaisons de mesures expérimentales avec les prédictions numériques ont permis de valider le modèle théorique ainsi que d'améliorer la compréhension des conditions de fonctionnement et d'alimentation de la zone d'étanchéité. / The great diversity of applications in all industrial fields, from the simplest to the most complex, whether for everyday use or for high-tech applications, requires the continuous design of increasingly efficient sealing systems. Pneumatic cylinders are fundamental elements of automation in a wide variety of industrial fields: lifting devices, robotics, aerospace, respiratory systems, etc. However, a sealing failure leads to lower performance and even malfunctions. Conversely, a better knowledge of the phenomena at the interfaces will allow the improvement of efficiency, the extension of the service life and of the reliability of the various pneumatic applications.This thesis work focuses on the experimental and numerical study of pneumatic seal systems. A modular test bench has been designed and built to allow the experimental investigation of different types of pneumatic seals, for a wide range of operating conditions, in terms of linear velocity, pneumatic pressure and constructive solutions. It mainly allows to characterize the friction of the joints but also the visualization of physical phenomena at the level of the sealing zone and its environment.In parallel, an ElastoHydroDynamic theoretical model, including the consideration of mixed lubrication conditions and the non-Newtonian rheological behaviour of lubricant (grease) has been developed. It is based on the coupling of a non-linear comercial software (allowing the modelling of the hyperelastic mechanical behaviour of the joints) and a thin film flow model. Comparisons of experimental measurements with numerical predictions validated the theoretical model and improved the understanding of the operating and supply conditions of the sealing area.