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.

The unsteady interaction of shock waves emerging from the trailing edge of modern turbine nozzle guide vanes and impinging on downstream rotor blades is modeled in a linear cascade. The Reynolds number based on blade chord and exit conditions (5*10^6) and the exit Mach number (1.2) are representative of modern engine operating conditions. The relative motion of shocks and blades is simulated by sending a shock wave along the leading edges of the linear cascade instead of moving the blades through an array of stationary shock waves. The blade geometry is a generic version of a modern high turning rotor blade with transonic exit conditions. The blade is equipped with a showerhead film cooling scheme. Heat flux, surface pressure and surface temperature are measured at six locations on the suction side of the central blade. Pressure measurements are taken with Kulite XCQ-062-50a high frequency pressure transducers. Heat flux data is obtained with Vatell HFM-7/L high speed heat flux sensors. High speed heat flux and pressure data are recorded during the time of the shock impact with and without film cooling. The data is analyzed in detail to find the relative magnitudes of the shock effect on the heat transfer coefficient and the recovery temperature or adiabatic wall temperature (in the presence of film cooling). It is shown that the variations of the heat transfer coefficient and the film effectiveness are less significant than the variations of recovery temperature. The effect of the shock is found to be similar in the cases with and without film cooling. In both cases the variation of recovery temperature induced by the shock is shown to be the main contribution to the overall unsteady heat flux. The unsteady heat flux is compared to results from different prediction models published in the literature. The best agreement of data and prediction is found for a model that assumes a constant heat transfer coefficient and a temperature difference calculated from the unsteady surface pressure assuming an isentropic compression. / Ph. D.

The single-plate interferometer is a powerful flow visualization and aerodynamic measurement tool. It can provide full-field data for the density distribution in a non-intrusive manner, and it can be used for highly unsteady flows. While the device itself represents a large decrease in complexity over other forms of interferometry, the data reduction procedure has traditionally been laborious and difficult. To remove these difficulties and to improve the accuracy of the Virginia Tech interferometer setup, the software has been revamped into a black box design removing the need to handle the code directly. Furthermore, the software has been made to be platform independent by implementing the algorithms using the Java programming language. New hardware has also been added which further simplifies the setup procedure. The improved setup and the new software is used to study the flow around a film cooled turbine blade in the Virginia Tech cascade wind tunnel. The study of this flowfield is used as a validation for the new algorithms and to illustrate the ease of use of the system. Through this analysis, the density distribution for the entire flowfield is acquired. Furthermore the use of Plexiglas as window material was tried. This proved to work, however the manufacturing processing of these windows proved relatively difficult. Studying the film layer close to the surface proved difficult because of inherent limitations with the single-plate interferometer. / Master of Science

Increased efficiency and durability of gas turbine components is driven by demands for reduced fuel consumption and increased reliability in aircraft and power generation applications. The complex flow near the endwall of an axial gas turbine has been identified as a significant contributing factor to aerodynamic loss and increased part temperatures. Three-dimensional (non-axisymmetric) contouring of the endwall surface has been shown to reduce aerodynamic losses, but the effect of the contouring on endwall heat transfer is not well understood. This research focused on understanding the general flow physics of contouring and the sensitivity of the contouring to perturbations arising from leakage features present in an engine. Two scaled low-speed cascades were designed for spatially-resolved measurements of endwall heat transfer and film cooling. One cascade was intended for flat and contoured endwall studies without considering typical engine leakage features. The other cascade modeled the gaps present between a stator and rotor and between adjacent blades on a wheel, in addition to the non-axisymmetric endwall contouring. Comparisons between a flat and contoured endwall showed that the contour increased endwall heat transfer and increased turbulence in the forward portion of the passage due to displacement of the horseshoe vortex. However, the contour decreased heat transfer further into the passage, particularly in regions of high heat transfer, due to delayed development of the passage vortex and reduced boundary layer skew. Realistic leakage features such as the stator-rotor rim seal had a significant effect on the endwall heat transfer, although leakage flow from the rim seal only affected the horseshoe vortex. The contours studied were not effective at reducing the impact of secondary flows on endwall heat transfer and loss when realistic leakage features were also considered. The most significant factor in loss generation and high levels of endwall heat transfer was the presence of a platform gap between adjacent airfoils. / Ph. D.

Efficiency and power output of gas turbines improve with an increase in turbine inlet temperatures, and blade designers continually seek out new methods of increasing these temperatures. Increases in turbine inlet temperatures are achieved by utilizing a combination of internal convective cooling and external film-cooling. This study will evaluate several novel cooling schemes for turbine airfoils, called microcircuits. Microcircuits are placed inside the turbine blade wall, and the features turbulate the air and increase heat transfer surface area, thereby augmenting convective cooling. The coolant flow then exits internal cooling passages to the external side of the blade. Here the coolant forms a protective layer along the external surface of the blade to protect the blade from the heated mainstream flow. In the current study, a low-speed large-scale wind tunnel facility was developed to measure internal heat transfer coefficients and external adiabatic effectiveness, using thermal liquid crystallography and infrared thermography. This test facility is unique in that it can be used to test the effects of internal cooling features on external film cooling. Results show that the highest augmentations in internal heat transfer were seen at the lowest Reynolds numbers. Internal features affected the shapes of external film-cooling contours, but the magnitudes of the spanwise averaged values did not change significantly with changes in internal geometry. / Master of Science

In a gas turbine engine, turbine blades are exposed to temperatures above their melting point. Film-cooling and internal cooling techniques can prolong blade life and allow for higher engine temperatures. This study examines a novel cooling technique called a microcircuit, which combines internal convection and pressure side injection on a turbine blade tip. Holes on the tip called dirt purge holes expel dirt from the blade, so other holes are not clogged. Wind tunnel tests are used to observe how effectively dirt purge and microcircuit designs cool the tip. Tip gap size and blowing ratio are varied for different tip cooling configurations. Results show that the dirt purge holes provide significant film cooling on the leading edge with a small tip gap. Coolant injected from these holes impacts the shroud and floods the tip gap reducing tip leakage flow. With the addition of a microcircuit, coolant is delivered to a larger area of the tip. In all cases, cooling levels are higher for a small tip gap than a large tip gap. Increased blowing ratio does not have a dramatic effect on microcircuit film-cooling at the midchord but does improve internal cooling from the microcircuit. While the combined dirt purge holes and microcircuit cool the leading edge and midchord areas, there remains a small portion of the trailing edge that is not cooled. Also, results suggest that blowing from the microcircuit diminishes the tip leakage vortex. Overall, the microcircuit appears to be a feasible method for prolonging blade life. / Master of Science

Gas turbine blades are subject to harsh operating conditions that require innovative cooling techniques to insure reliable operation of parts. Film-cooling and internal cooling techniques can prolong blade life and allow for higher engine temperatures. This study examines several unique methods of cooling the turbine blade tip. The first method employs holes placed directly in the tip which inject coolant onto the blade tip. The second and third methods used holes placed on the pressure side of a blade near the tip representative of two different manufacturing techniques. The fourth method is a novel cooling technique called a microcircuit, which combines internal convection and injection from the pressure side near a turbine blade tip. Wind tunnel tests are used to observe how effectively these designs cool the tip through adiabatic effectiveness measurements and convective heat transfer measurements. Tip gap size and blowing ratio are varied for the different tip cooling configurations. Results from these studies show that coolant injection from either the tip surface or from the pressure side near the tip are viable cooling methods. All of these studies showed better cooling could be achieved at small tip gaps than large tip gaps. The results in which the two different manufacturing techniques were compared indicated that the technique producing more of a diffused hole provided better cooling on the tip. When comparing the thermal performance of all the cooling schemes investigated, the added benefit of the internal convective cooling shows that the microcircuit outperforms the other designs. / Master of Science

Cooling of turbine parts in a gas turbine engine is necessary for operation as the temperature of combustion gases is higher than the melting temperature of the turbine materials. The gap between rotating turbine blades and the stationary shroud provides an unintended flow path for hot gases. Gases that flow through the tip region cause pressure losses in the turbine section and high heat loads to the blade tip. This thesis studies the heat transfer on an innovative tip geometry intended to help reduce aerodynamic losses. The blade tip has a depression (shelf) on the tip surface along much of the pressure side of the blade and film-cooling holes along the depression. This research experimentally measured the effect of the shelf, coolant flow and tip gap on heat transfer on the blade tip. Stationary experiments were performed in a low speed wind tunnel on a linear cascade with two different tip gaps and multiple coolant flow rates through the film-cooling holes. Tests showed that baseline Nusselt numbers on the tip surface were reduced with the shelf tip compared with a flat tip. Measurements indicated that film-cooling was more effective with a small tip gap than with a large tip gap. Experimental and computational results demonstrated a lack of coolant spreading that was detrimental to regions between the film-cooling holes. While the coolant was effective on the blade tip, the leading and trailing edge regions were found to have high heat transfer coefficients with little available cooling. / Master of Science

Heat transfer experiments were done on a flat plate to study the effect of internal counter-flow backside cooling on adiabatic film cooling effectiveness and heat transfer coefficient. In addition, the effects of density ratio (DR), blowing ratio (BR), diagonal length over diameter (L/D) ratio, and Reynolds number were studied using this new configuration. The results are compared to a conventional plenum fed case. Data were collected up to X/D =23 where X=0 at the holes, an S/D = 1.65 and L/D=1,2. Testing was done at low L/D ratios since short holes are normally found in double wall cooling applications in turbine components. A DR of 2 was used in order to simulate engine-like conditions and this was compared to a DR of 0.92 since relevant research is done at similar low DR. The BR range of 0.5 to 1.5 was chosen to simulate turbine conditions as well. In addition, previous research shows that peak effectiveness is found within this range. Infrared (IR) thermography was used to capture temperature contours on the surface of interest and the images were calibrated using a thermocouple and data analyzed through MATLAB software. A heated secondary fluid was used as 'coolant' in the present study. A steady state heat transfer model was used to perform the data reduction procedure. Results show that backside cooling configuration has a higher adiabatic film cooling effectiveness when compared to plenum fed configurations at the same conditions. In addition, the trend for effectiveness with varying BR is reversed when compared with traditional plenum fed cases. Yarn flow visualization tests show that flow exiting the holes in the backside cooling configuration is significantly different when compared to flow exiting the plenum fed holes. We hypothesize that backside cooling configuration has flow exiting the holes in various directions, including laterally, and behaving similar to slot film cooling, explaining the differences in trends. Increasing DR at constant BR shows an increase in adiabatic effectiveness and HTC in both backside cooling and plenum fed configurations due to the decreased momentum of the coolant, making film attachment to the surface more probable. The effects of L/D ratio in this study were negligible since both ratios used were small. This shows that the coolant flow is still underdeveloped at both L/D ratios. The study also showed that increasing turbulence through increasing Reynolds number decreased adiabatic effectiveness. / MS / Gas turbine engines are used for multiple applications for power (power plants) or thrust (aircraft propulsion). Engine efficiency is correlated with higher working temperatures, which exceed the melting points of the materials being used. Therefore, more efficient cooling techniques are needed in order to protect the engine turbine components, such as blades and vanes. Relatively cooler air is bypassed from the compressor to the turbine section to cool the turbine components from the high temperatures. The air flows through the turbine components and out through machined holes referred to as film cooling holes. A protective layer, or film, protects the external region of the blade or vane. Previous research has found that the geometry of the airfoils used and the flow conditions play a major role in heat transfer. Most of the relevant research use a model that contains one-sided heat transfer. The present study focuses on combined backside and film cooling heat transfer, with different geometries and flow conditions, using a steady-state model for the data reduction procedure.

This work presents a comparison of thin film gauge (TFG) and infrared (IR) thermography measurement techniques to simultaneously determine heat transfer coefficient and film cooling effectiveness. The first comparison was with an uncooled vane where heat transfer coefficient was measured at Mex=0.77 and Tu=16%. Relatively good agreement was found between the results of the two methods and the effect of recovery temperature and data reduction time was analyzed. Improvements were made to the experimental set up for the next comparison, a showerhead film cooled vane. This geometry was tested at BR=0, 2.0, Mex=0.76 and Tu=16%. The TFG and IR results did not compare well for heat transfer coefficient or film cooling effectiveness. The effects of measured and calculated recovery temperature were analyzed as well as the respective data reduction methods, though the analysis could not account for the effectiveness trend seen on the suction surface. Finally, a vane with showerhead and shaped film cooling holes were presented at BR=0, 1.7, 2.0, 2.8, Mex=0.85, and Tu=13% to assess a new film cooling geometry measured with the IR technique. Similarities on the suction surface trend between the different film cooled geometries tested with IR indicate a flaw in the experiment that will require further analysis, changes and testing to complete the comparison with TFG. / Master of Science