The effect of global warming due to increased level of greenhouse gas emissions from coal fired thermal power plants and crisis of reliable energy resources has profoundly increased the importance of natural gas based power generation as a major alternative in the last few decades. Although gas turbine propulsion system had been primarily developed and technological advancements over the years had focused on application in civil and military aviation industry, use of gas turbine engines for land based power generation has emerged as the most promising candidate due to higher thermal efficiency, abundance of natural gas resources, development in generation of hydrogen rich synthetic fuel (Syngas) using advanced gasification technology for further improved emission levels and strict enforcement in emission regulations on installation of new coal based power plants. The fundamental thermodynamic principle behind gas turbine engines is Brayton cycle and higher thermal efficiency is achieved through maximizing the Turbine Inlet Temperature (TIT). Modern gas turbine engines operate well beyond the melting point of the turbine component materials to meet the enhanced efficiency requirements especially in the initial high pressure stages (HPT) after the combustor exit. Application of thermal barrier coatings (TBC) provides the first line of defense to the hot gas path components against direct exposure to high temperature gases. However, a major portion of the heat load to the airfoil and passage is reduced through injection of secondary air from high pressure compressor at the expense of a penalty on engine performance. External film cooling comprises a significant part of the entire convective cooling scheme. This can be achieved injecting coolant air through film holes on airfoil and endwall passages or utilizing the high pressure air required to seal the gaps and interfaces due to turbine assembly features. The major objective is to maximize heat transfer performance and film coverage on the surface with minimum coolant usage. Endwall contouring on the other hand provides an effective means of minimizing heat load on the platform through efficient control of secondary flow vortices. Complex vortices form due to the interaction between the incoming boundary layer and endwall-airfoil junction at the leading edge which entrain the hot gases towards the endwall, thus increasing surface heat transfer along its trajectory. A properly designed endwall profile can weaken the effects of secondary flow thereby improving the aerodynamic and associated heat transfer performance. This dissertation aims to investigate heat transfer characteristics of a non-axisymmetric contoured endwall design compared to a baseline planar endwall geometry in presence of three major endwall cooling features – upstream purge flow, discrete hole film cooling and mateface gap leakage under transonic operating conditions. The preliminary design objective of the contoured endwall geometry was to minimize stagnation and secondary aerodynamic losses. Upstream purge flow and mateface gap leakage is necessary to prevent ingestion to the turbine core whereas discrete hole cooling is largely necessary to provide film cooling primarily near leading edge region and mid-passage region. Different coolant to mainstream mass flow ratios (MFR) were investigated for all cooling features at design exit isentropic Mach number (0.88) and design incidence angle. The experiments were performed at Virginia Tech's quasi linear transonic blow down cascade facility. The airfoil span increases in the mainstream flow direction in order to match realistic inlet/exit airfoil surface Mach number distribution. A transient Infrared (IR) thermography technique was employed to measure the endwall surface temperature and a novel heat transfer data reduction method was developed for simultaneous calculation of heat transfer coefficient (HTC) and adiabatic cooling effectiveness (ETA), assuming a 1D semi-infinite transient conduction. An experimental study on endwall film cooling with endwall contouring at high exit Mach numbers is not available in literature. Results indicate significant benefits in heat transfer performance using the contoured endwall in presence of individual (upstream slot, discrete hole and mateface gap) and combined (upstream slot with mateface gap) cooling flow features. Major advantages of endwall contouring were observed through reduction in heat transfer coefficient and increase in coolant film coverage by weakening the effects of secondary flow and cross passage pressure differential. Net Heat Flux Reduction (NHFR) analysis was carried out combining the effect of heat transfer coefficient and film cooling effectiveness on both endwall geometries (contoured and baseline) where, the contoured endwall showed major improvement in heat load reduction near the suction side of the platform (upstream leakage only and combined upstream with mateface leakage) as well as further downstream of the film holes (discrete hole film cooling). Detailed interpretation of the heat transfer results along with near endwall flow physics has also been discussed. / Ph. D.

Gas turbine companies are always focused on reducing capital costs and increasing overall efficiency. There are numerous advantages in reducing the number of airfoils per stage in the turbine section. While increased airfoil loading offers great advantages like low cost and weight, they also result in increased aerodynamic losses and associated issues. The strength of secondary flows is influenced by the upstream boundary layer thickness as well as the overall flow turning angle through the blade row. Secondary flows result in stagnation pressure loss which accounts for a considerable portion of the total stagnation pressure loss occurring in a turbine passage. A turbine designer strives to minimize these aerodynamic losses through design changes and geometrical effects. Performance of airfoils with varying loading levels and turning angles at transonic flow conditions are investigated in this study. The pressure difference between the pressure side and suction side of an airfoil gives an indication of the loading level of that airfoil. Secondary loss generation and the 3D flow near the endwalls of turbine blades are studied in detail. Detailed aerodynamic loss measurements, both in the pitchwise as well as spanwise directions, are conducted at 0.1 axial chord and 1.0 axial chord locations downstream of the trailing edge. Static pressure measurements on the airfoil surface and endwall pressure measurements were carried out in addition to downstream loss measurements. The application of endwall contouring to reduce secondary losses is investigated to try and understand when contouring can be beneficial. A detailed study was conducted on the effectiveness of endwall contouring on two different blades with varying airfoil spacing. Heat transfer experiments on the endwall were also conducted to determine the effect of endwall contouring on surface heat transfer distributions. Heat transfer behavior has significant effect on the cooling flow needs and associated aerodynamic problems of coolant-mainstream mixing. One of the primary objectives of this study is to provide data under transonic conditions that can be used to confirm/refine loss predictions for the effect of various Mach numbers and gas turning. The cascade exit Mach numbers were varied within a range from 0.6 to 1.1. A published experimental study on the effect of end wall contouring on such high turning blades at high exit Mach numbers is not available in open literature. Hence, the need to understand the parametric effects of endwall contouring on aerodynamic and heat transfer performance under these conditions. / Ph. D.

Airfoil endwall contouring has been widely studied during the past two decades for the reduction of secondary losses in turbine passages. Although many endwall contouring methods have been suggested by researchers, an analytical tool based on the passage design parameters is still not available for designers. Hence, the best endwall contour shape is usually decided through an optimization study. Moreover, a general guideline for the endwall shape variation can be extrapolated from the existing literature. It has not been validated whether the optimum endwall shape for one passage can be fitted to other similar passage geometry to achieve, least of all a non-optimum but a definite, reduction in losses. Most published studies were conducted at low exit Mach numbers and only recently some studies on the effect of endwall contouring on aerodynamics performance of a turbine passage at high exit Mach numbers have been published. There is, however, no study available in the open literature for a very high turning blade with a transonic design exit Mach number and the effect of endwall contouring on the heat transfer performance of a turbine passage. During the present study, a robust, aerodynamic performance based numerical optimization methodology for turbine endwall contouring has been developed. The methodology is also adaptable to a range of geometry optimization problems in turbomachinery. It is also possible to use the same methodology for multi-objective aero-thermal optimization. The methodology was applied to a high turning transonic turbine blade passage to achieve a geometry based on minimum total pressure loss criterion. The geometry was then compared with two other endwall geometries. The first geometry is based on minimum secondary kinetic energy value instead of minimum total pressure loss criterion. The second geometry is based on a curve combination based geometry generation method found in the literature. A normalized contoured surface topology was extracted from a previous study that has similar blade design parameters. This surface was then fitted to the turbine passage under study in order to investigate the effect of such trend based surface fitting. Aerodynamic response of these geometries has been compared in detail with the baseline case without any endwall contouring. A new non-contoured baseline design and two contoured endwall designs were provided by Siemens Energy, Inc. The pitch length for these designs is about 25% higher than the turbine passage used for the endwall optimization study. The aerodynamic performance of these endwalls was studied through numerical simulations. Heat transfer performance of these endwall geometries was experimentally investigated in the transonic turbine cascade facility at Virginia Tech. One of the contoured geometries was based on optimum aerodynamic loss reduction criterion while the other was based on optimum heat transfer performance criterion. All the three geometries were experimentally tested at design and off-design Mach number conditions. The study revealed that endwall contouring results in significant performance benefit from the heat transfer performance point of view. / Ph. D.

The present study investigates mixed out aerodynamic loss coefficient measurements for a high turning, contoured endwall passage under transonic operating conditions in presence of upstream purge slot and mateface gap. The upstream purge slot represents the gap between stator-rotor interface and the mateface gap simulates the assembly feature between adjacent airfoils in an actual high pressure turbine stage. While the performance of the mateface and upstream slot has been studied for lower Mach number, no studies exist in literature for transonic flow conditions. Experiments were performed at the Virginia Tech's linear, transonic blow down cascade facility. Measurements were carried out at design conditions (isentropic exit Mach number of 0.87, design incidence) without and with coolant blowing. Upstream leakage flow of 1.0% coolant to mainstream mass flow ratio (MFR) was considered with the presence of mateface gap. There was no coolant blowing through the mateface gap itself. Cascade exit pressure measurements were carried out using a 5-hole probe traverse at a plane 1.0Cax downstream of the trailing edge for a planar geometry and two contoured endwalls. Spanwise measurements were performed to complete the entire 2D loss plane from endwall to midspan, which were used to plot pitchwise averaged losses for different span locations and loss contours for the passage. Results reveal significant reduction in aerodynamic losses using the contoured endwalls due to the modification of flow physics compared to a non contoured planar endwall. / Master of Science

Thesis (PhD) -- Stellenbosch University, 2014. / ENGLISH ABSTRACT: With increasing environmental concerns and the drive for a greener economy comes an increased desire to improve turbine engine fuel efficiency and reduce emissions. Unfortunately weight reduction techniques used increase the blade loading, which in turn increases the losses. Non-axisymmetric endwall contouring is one of several techniques being investigated to reduce loss in a turbine. An investigation at Durham University produced a non-axisymmetric endwall design for a linear cascade. An adaption of the most promising endwall was investigated in an annular rotating test rig at the CSIR using steady state instrumentation. The current investigation extends those investigations into the unsteady time domain. Previous investigations found that a generic rotor endwall contour improved efficiency by controlling the endwall secondary flow vortex system in both a linear cascade and an annular 1½ stage rotating test turbine. The current research was aimed at determining if there were any unsteady effects introduced by the contoured endwall. The approach was unique in that it investigated the unsteady effects of an endwall contour originally designed for a linear cascade both experimentally and numerically at three incidence angles (positive, zero and negative to represent increased load, design load and decreased load respectively), the results of which are openly available. Unsteady experimental hotfilm results showed that the endwall contour made the velocity profile more radially uniform by reducing the strength of the endwall secondary flow vortex system. The fluctuations in the velocity were also reduced producing a more temporally uniform velocity profile. The FFT magnitude of the velocity at the blade passing frequency below midspan was also reduced. It was found that the reduction in the endwall secondary flow vortex system due to the contour increased with increasing loading. Numerical results showed that the oscillations in the flow were small and did not penetrate the boundary layer. The contoured rotor was forward and aft loaded when compared to the annular rotor, resulting in a weaker cross passage pressure gradient which allowed the endwall secondary flow vortex system to be less tightly wrapped. Numerical results did not show a significant difference in the oscillations observed in the annular and contoured rotor. A new objective function for use in the endwall optimisation process was proposed that acts as a proxy for efficiency, but is less prone to uncertainty in the results. When used on the current results it shows the same trend as efficiency. It remains to be used to design an endwall for full validation. / AFRIKAANSE OPSOMMING: Met ’n toenemende omgewingsbesorgdheid en die strewe na ’n groener ekonomie kom ’n toenemende behoefte om turbine enjin brandstofdoeltreffendheid te verbeter en vrystellings te verlaag. Ongelukkig het gewigsbesparingstegnieke wat gebruik is die lemlading verhoog, wat op sy beurt die verliese verhoog. Nie-assimmetriese endwandprofilering is een van verskeie tegnieke wat ondersoek word om verliese in ’n turbine te verminder. ’n Ondersoek by die Universiteit van Durham het ’n nie-assimmetriese endwandontwerp vir ’n lineêre kaskade gelewer. ’n Aanpassing van die mees belowende endwand is in ’n annulêre roterende toetsopstelling by die WNNR getoets, deur gebruik te maak van bestendige toestand instrumentasie. Die huidige ondersoek brei daardie ondersoeke uit na die nie-bestendige verwysingsraamwerk . Vorige ondersoeke het bevind dat die generiese rotor endwandprofiel doeltreffendheid verbeter as gevolg van die beheer van die endwand sekondêre vloei draaikolkstelsel in beide ’n lineêre kaskade sowel as ’n annulêre 1½ stadium roterende toetsturbine. Die huidige navorsing was daarop gemik om vas te stel of die endwandprofiel enige onbestendige effekte tot gevolg gehad het. Die benadering was uniek in die sin dat dit die onbestendige effekte ondersoek het van ’n endwandprofiel wat oorspronklik ontwerp is vir ’n lineêre kaskade beide eksperimenteel en numeries op drie invalsshoeke (positief, nul en negatief om onderskeidelik verhoogde lading, ontwerplading en verlaagde lading te verteenwoordig), waarvan die resultate algemeen beskikbaar is. Onbestendige eksperimentele warmfilm resultate het getoon dat die endwandprofiel die snelheidsprofiel meer radiaal uniform gemaak het deur die vermindering van die sterkte van die endwand sekondêre vloei werwelstelsel. Die skommelinge in die snelheid is ook verminder wat ’n meer tyduniforme snelheidsprofiel gelewer het. Die FFT (Fast Fourier Transform) grootte van die snelheid van die lem verbygaan frekwensie onder lem midbestek het ook verminder. Daar was bevind dat die vermindering in die endwand sekondêre vloei draaikolkstelsel as gevolg van die endwandprofiel toeneem met toenemende lading. Numeriese resultate het getoon dat die ossilasie in die vloei klein was en nie die grenslaag binnegedring het nie. Die rotor met gevormde wand het ’n voor- en agterlading gehad in vergelyking met die rotor met annulêre wand, wat tot ’n laer drukgradient dwarsop die vloeirigting gelei het, die endwand sekondêre vloei draaikolkstelsel minder beperk het. Numeriese resultate het nie ’n beduidende verskil in die ossilasies tussen die annulêre en gevormde rotorwand getoon nie. ’n Nuwe doelwitfunksie vir gebruik in die endwand optimersproses is voorgestel wat dien as ’n plaasvervanger vir doeltreffendheid, maar minder geneig is tot onsekerheid in die resultate. Wanneer dit gebruik word op die huidige resultate toon dit dieselfde tendens as doeltreffendheid. Dit moet nog gebruik word in die ontwerp van ’n endwand vir volledige bevestiging.

<p>In rotating detonation engines the turbine inlet conditions may be transonic with unprecedented unsteady fluctuations, very different from those in conventional high-pressure turbines. To ensure an acceptable engine performance, the turbine passages must be unchoked at subsonic and started at supersonic conditions. Additionally, to maximize the aerodynamic performance potential, ad-hoc designs are required, suited for the oscillations in Mach number and flow angle. This manuscript focuses on designing and characterizing diffusive turbine vanes that can operate downstream of a transonic rotating detonation combustor.  </p> <p><br></p> <p>First, the phenomenon of unstarting is presented, concentrating on the effect of pressure loss on the accurate prediction of the starting limit. Afterward, a multi-objective optimization with steady Reynolds Averaged Navier Stokes simulations, including the endwall and 3D vane design, is performed. The results are discussed, highlighting the impact of the throat-to-inlet area ratio on the pressure loss and the geometric features of the top-performing designs. Compared to previous  research on stator passages with contoured endwalls, considerable reductions in pressure loss and stator-induced rotor forcing are obtained, with an extended operating range and preserving high turning.  </p> <p><br></p> <p>Subsequently, the influence of the inlet boundary layer thickness on the vane performance is evaluated, inducing remarkable increases in pressure loss and downstream pressure distortion. Employing an optimization with a thicker inlet boundary layer, specific endwall design recommendations are found, providing a notable improvement in both objective functions. The impact of the geometry variations on flow detachment is assessed as well.</p> <p><br></p> <p>Finally, the impact of the inlet flow angle on the vane design is studied through a multi-point, multi-objective optimization with different inlet angles. The effect of incidence on the flow field and vane performance is evaluated first. Then, by comparing the optimized geometries with those optimized for axial inflows, several design guidelines are identified </p>