Over the last two decades, most developed countries have reached a consensus that greener energy production is necessary for the world, due to the climate changes and limited fossil fuel resources. More efficient turbine is desirable and can be archived by higher turbine-inlet temperature (TIT). However, it is difficult for nozzle guide vane (NGV), which is the first stage after combustion chamber, to withstand a very high temperature. Thus, cooling methods such as film cooling have to be implemented. Film-cooled NGV of an annular sector cascade (ASC) is studied in this thesis, for getting comprehensive calculation of vorticity, and analyzing applicability of existing loss models, namely Hartsel model and Young & Wilcock model. The flow-field calculation methods from previously published studies are reviewed. Literatures focusing on Hartsel model and Young & Wilcock model are studied. Measurement data from previously published studies are analyzed and compared with the loss models. In order to get experience of how measurements take place, participation of a test run experiment is involved. Calculation of flow vector has been evaluated and modified. Actual flow angle is introduced when calculating velocity components. Thus, more exact results are obtained from the new method. Calculation of vorticity has been evaluated and made more comprehensive. Vorticity components as well as magnitude of total streamwise vorticity are calculated and visualized. Vorticity is higher and more extensive for fully cooled case than uncooled case. Highest vorticity is found at regions near the hub, tip and TE. Axial and circumferential vorticities show similar patterns, while the radial vorticity is relatively simpler. Compressibility is introduced as a new method when calculating circumferential and radial vorticities, resulting more extensive and higher vorticities than results from incompressible solutions. Hartsel model and Young & Wilcock model have been evaluated and compared to the ASC to see the applicability of the models. In general, Hartsel model cannot agree with the ASC to a satisfactory level and thus cannot be applied. Coolant velocity is found to be the dominant factor of Hartsel model. Young & Wilcock model may match SS1 and SS2 cases, or even PS and SH4 cases, but cannot match TE case. The applicability of Young & Wilcock model is much dependent on the location of cooling rows.

A methodology is formulated for the solution of the inverse problem concerned with the reconstruction of multi-dimensional heat fluxes for film cooling applications. The motivation for this study is the characterization of complex thermal conditions in industrial applications such as those encountered in film cooled turbomachinery components. The heat conduction problem in the metal endwall/shroud is solved using the boundary element method (bem), and the inverse problem is solved using a genetic algorithm (ga). Thermal conditions are overspecified at exposed surfaces amenable to measurement, while the temperature and surface heat flux distributions are unknown at the film cooling hole/slot walls. The latter are determined in an iterative process by developing two approaches. The first approach, developed for 2d applications, solves an inverse problem whose objective is to adjust the film cooling hole/slot wall temperatures and heat fluxes until the temperature and heat flux at the measurement surfaces are matched in an overall heat conduction solution. The second approach, developed for 2d and 3d applications, is to distribute a set of singularities (sinks) at the vicinity of the cooling slots/holes surface inside a fictitious extension of the physical domain or along cooling hole centerline with a given initial strength distribution. The inverse problem iteratively alters the strength distribution of the singularities (sinks) until the measuring surfaces heat fluxes are matched. The heat flux distributions are determined in a post-processing stage after the inverse problem is solved. The second approach provides a tremendous advantage in solving the inverse problem, particularly in 3d applications, and it is recommended as the method of choice for this class of problems. It can be noted that the ga reconstructed heat flux distributions are robust, yielding accurate results to both exact and error-laden inputs. In all cases in this study, results from experiments are simulated using a full conjugate heat transfer (cht) finite volume models which incorporate the interactions of the external convection in the hot turbulent gas, internal convection within the cooling plena, and the heat conduction in the metal endwall/shroud region. Extensive numerical investigations are undertaken to demonstrate the significant importance of conjugate heat transfer in film cooling applications and to identify the implications of various turbulence models in the prediction of accurate and more realistic surface temperatures and heat fluxes in the cht simulations. These, in turn, are used to provide numerical inputs to the inverse problem. Single and multiple cooling slots, cylindrical cooling holes, and fan-shaped cooling holes are considered in this study. The turbulence closure is modeled using several two-equation approach, the four-equation turbulence model, as well as five and seven moment reynolds stress models. The predicted results, by the different turbulence models, for the cases of adiabatic and conjugate models, are compared to experimental data reported in the open literature. Results show the significant effects of conjugate heat transfer on the temperature field in the film cooling hole region, and the additional heating up of the cooling jet itself. Moreover, results from the detailed numerical studies presented in this study validate the inverse problem approaches and reveal good agreement between the bem/ga reconstructed heat fluxes and the cht simulated heat fluxes along the inaccessible cooling slot/hole walls

Conjugate heat transfer analysis has been carried out on an 89kN thrust chamber in order to evaluate whether combined discrete film cooling and regenerative cooling in a rocket nozzle is feasible. Several cooling configurations were tested against a baseline design of regenerative cooling only. New designs include combined cooling channels with one row of discrete film cooling holes near the throat of the nozzle, and turbulated cooling channels combined with a row of discrete film cooling holes. Blowing ratio and channel mass flow rate were both varied for each design. The effectiveness of each configuration was measured via the maximum hot gas-side nozzle wall temperature, which can be correlated to number of cycles to failure. A target maximum temperature of 613K was chosen. Combined film and regenerative cooling, when compared to the baseline regenerative cooling, reduced the hot gas side wall temperature from 667K to 638K. After adding turbulators to the cooling channels, combined film and regenerative cooling reduced the temperature to 592K. Analysis shows that combined regenerative and film cooling is feasible with significant consequences, however further improvements are possible with the use of turbulators in the regenerative cooling channels.

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The work presented in this dissertation is the first numerical investigation conducted to study leading edge film cooling with Large Eddy Simulation (LES). A cylindrical leading edge with a flat after-body represents the leading edge, where coolant is injected with a 30Ë compound angle. Three blowing ratios of 0.4, 0.8, and 1.2 are studied. Free-stream Reynolds number is 100,000 and coolant-to-mainstream density ratio is unity. At blowing ratio of 0.4, the effect of coolant inlet condition is investigated. Results show that the fully-turbulent coolant jet increases mixing with the mainstream in the outer shear layer but does not influence the flow dynamics in the turbulent boundary layer at the surface. As a result, the turbulent jet decreases adiabatic effectiveness but does not have a substantial effect on the heat transfer coefficient. At B.R.=0.4, three types of coherent structures are identified which consist of a primary entrainment vortex at the leeward aft-side of the coolant hole, vortex tubes at the windward side of the coolant hole, and hairpin vortices typical of turbulent boundary layers produced by the turbulent interaction of the coolant and mainstream downstream of injection. At B.R. = 0.8 and 1.2, coherent vortex tubes are no longer discernable, whereas the primary vortex structure gains in strength. In all cases, the bulk of the mixing occurs by entrainment which takes place at the leeward aft-side of the coolant jet. This region is characterized by a low pressure core and the primary entrainment vortex. Turbulent shear interaction between coolant jet and mainstream increases substantially with blowing ratio and contributes to the dilution of the coolant jet. As a result of the increased mixing in the shear layer and primary structure, adiabatic effectiveness decreases and heat transfer coefficient increases with increase in blowing ratio. The dissertation also investigates the deposition and erosion of Syngas ash particles in the film cooled leading edge region. Three ash particle sizes of 1, 5, and 10 microns are investigated at all blowing ratios using Lagrangian dynamics. The 1 micron particles with momentum Stokes number St = 0.03 (based on approach velocity and cylinder diameter), show negligible deposition/erosion. The 10 micron particles, on the other hand with a high momentum Stokes number, St = 3, directly impinge and deposit on the surface, with blowing ratio having a minimal effect. The 5 micron particles with St=0.8, show the largest receptivity to coolant flow and blowing ratio. On a mass basis, 90% of deposited mass is from 10 micron particles, with 5 micron particles contributing the other 10%. Overall there is a slight decrease in deposited mass with increase in blowing ratio. About 0.03% of the total incoming particle energy can potentially be transferred as erosive energy to the surface and coolant hole, with contribution coming from only 5 micron particles at B.R.=0.4 and 0.8, and both 5 and 10 micron particles at B.R.=1.2. / Ph. D.

Modern gas turbine designs' ever-increasing turbine inlet temperature raises challenges for the nozzle guide vane cooling. Two typical endwall cooling schemes, jump cooling and louver cooling, result in different interactions between the injected coolant and the mainstream, leading to different cooling effects. This study investigates these two cooling schemes on the endwall cooling experimentally and numerically. Wind tunnel tests and the CFD simulations are carried out with engine-representative conditions of an exit Mach number of 0.85, an exit Reynolds number of 1.5×10^6, and an inlet Turbulence intensity of 16%. The jump cooling scheme experiments investigate two blowing ratios, 2.5 and 3.5, two density ratios, 1.2 and 1.95, and three endwall profiles with different NGV-turbine alignments. Four coolant mass flow ratios from 1.0% to 4.0% are tested for the louver cooling. The results show that the cavity vortex, the horseshoe vortex, and the passage vortex are the main factors that prevent the upstream coolant from reaching the NGV passage. The jump cooling scheme generally provides high momentum to the cooling jets. As a result, the coolant at the design case density ratio of 1.95 and blowing ratio of 2.5 is sufficiently energized to penetrate the horseshoe vortex. It then forms a relatively uniform coolant film near the NGV passage inlet, leading to a minimum adiabatic cooling effectiveness of 0.4 throughout the passage. Reducing the coolant density or increasing the blowing ratio leads to higher coolant momentum, so the coolant jets can further suppress the horseshoe vortex. However, high momentum may cause coolant lift-off, mitigating the coolant reattachment. Therefore, the density ratio needs to be carefully balanced with the blowing ratio to optimize the cooling effect. This balance is also affected by the combustor-NGV misalignment, as a higher step height requires higher coolant momentum to overcome the step-induced vortices. On the contrary, the louver cooling scheme provides less momentum to the coolant. The results showed that only by exceeding a coolant mass flow rate of 1~2% can the coolant form a uniform film which provides good coverage upstream of the NGV passage inlet. As for the cooling of the NGV passage, the mass flow rate ratio of the range investigated is not sufficient for desirable cooling performance. The pressure side endwall proves most difficult for the coolant to reach. In addition, the fishmouth cavity at the combustor-NGV passage causes a three-dimensional cavity vortex that transports the coolant in the pitch-wise direction. Moreover, the coolant transport pattern is dependent on the coolant blow rate. Overall, the more-energized coolant film generated by the jump cooling tends to survive longer, but it is also more prone to lift-off. At the same time, the less-energized coolant film caused by the louver cooling is more susceptible to vortices and the discontinuity of the endwall geometry. However, it develops faster, especially in the lateral direction. The two schemes could be applied simultaneously for an ideal cooling system. The jump cooling can provide enough momentum for the coolant to persist in the NGV passage. Meanwhile, the louver cooling covers the upstream region before the jump cooling coolant reattaches to the endwall. / Doctor of Philosophy / Gas turbines, sometimes called combustion turbines, are widely used to generate power or propulsion for various applications. The three main components of a gas turbine are compressor, combustor, and turbine. Modern gas turbines run at a high turbine inlet temperature that exceeds the current metal limits to increase efficiency. However, this brings significant challenges to the cooling of the first stage of the turbine, the nozzle guide vane. In this research, two commonly used endwall cooling methods, jump cooling and louver cooling, are investigated under engine-representative conditions experimentally and numerically. In addition, flow physics is demonstrated to explain the endwall cooling performance, mainly the upstream boundary layer caused by the interaction between the mainstream and the coolant flow. The results show that the cavity vortex, the horseshoe vortex, and the passage vortex are the main factors that prevent the upstream coolant from reaching the NGV passage. The jump cooling scheme provides high momentum to the cooling jets. As a result, the coolant in the design case is sufficiently energized to penetrate the horseshoe vortex, providing a desirable cooling effect in the NGV passage. Reducing the density ratio or increasing the blowing ratio can help the coolant jets further suppress the horseshoe vortex but also causes more lift-off, which adversely affects the cooling performance. On the contrary, the louver cooling scheme provides less momentum to the coolant, forming a less energized coolant film. The lack of coolant causes the louver coolant film to provide good coverage immediately downstream of the louver scheme exit. However, due to unfavorable interaction with vortices and endwall discontinuity, the cooling effect decays quickly downstream. Overall, the more-energized coolant film generated by the jump cooling tends to survive longer, but it is also more prone to lift-off. At the same time, the less-energized coolant film caused by the louver cooling is more susceptible to vortices and the discontinuity of the endwall geometry. However, it develops faster, especially in the lateral direction. The two schemes could be applied simultaneously for an ideal cooling system to work mutually beneficially.

Coal gasification and combustion can introduce contaminants in the solid or molten state depending on the gas clean up procedures used, coal composition and operating conditions. These byproducts when combined with high temperatures and high gas stream velocities can cause Deposition, Erosion, and Corrosion (DEC) of turbine components downstream of the combustor section. The objective of this dissertation is to use computational techniques to investigate the dynamics of ash deposition in a leading edge vane geometry with film cooling. Large Eddy Simulations (LES) is used to model the flow field of the coolant jet-mainstream interaction and the deposition of syngas ash in the leading edge region of a turbine vane is modeled using a Lagrangian framework. The three row leading edge vane geometry is modeled as a symmetric semi-cylinder with a flat afterbody. One row of coolant holes is located along the stagnation line and the other two rows of coolant holes are located at ±21.3° from the stagnation line. The coolant is injected at 45° to the vane surface with 90° compound angle injection. The coolant to mainstream density ratio is set to unity and the freestream Reynolds number based on leading edge diameter is 32000. Coolant to mainstream blowing ratios (B.R.) of 0.5, 1.0, 1.5, and 2.0 are investigated. It is found that the stagnation cooling jets penetrate much further into the mainstream, both in the normal and lateral directions, than the off-stagnation jets for all blowing ratios. Jet dilution is characterized by turbulent diffusion and entrainment. The strength of both mechanisms increases with blowing ratio. The adiabatic effectiveness in the stagnation region initially increases with blowing ratio but then generally decreases as the blowing ratio increases further. Immediately downstream of off-stagnation injection, the adiabatic effectiveness is highest at B.R.=0.5. However, in spite of the larger jet penetration and dilution at higher blowing ratios, the larger mass of coolant injected increases the effectiveness with blowing ratio further downstream of injection location. A novel deposition model which integrates different sources of published experimental data to form a holistic numerical model is developed to predict ash deposition. The deposition model computes the ash sticking probabilities as a function of particle temperature and ash composition. This deposition model is validated with available experimental results on a flat plate inclined at 45°. Subsequently, this model was then used to study ash deposition in a leading edge vane geometry with film cooling for coolant to mainstream blowing ratios of 0.5, 1.0, 1.5 and 2.0. Ash particle sizes of 5, 7, 10μm are considered. Under the conditions of the current simulations, ash particles have Stokes numbers less than unity of O(1) and hence are strongly affected by the flow and thermal fields generated by the coolant interaction with the main-stream. Because of this, the stagnation coolant jets are successful in pushing and/or cooling the particles away from the surface and minimizing deposition and erosion in the stagnation region. Capture efficiency for eight different ash compositions are investigated. Among all the ash samples, ND ash sample shows the highest capture efficiency due to its low softening temperature. A trend that is common to all particle sizes is that the percentage capture efficiency is least for blowing ratio of 1.5 as the coolant is successful in pushing the particles away from the surface. However, further increasing the blowing ratio to 2.0, the percentage capture efficiency increases as more number of particles are transported to the surface by strong mainstream entrainment by the coolant jets. / Ph. D.

This dissertation presents a detailed experimental and numerical analysis of the aerothermal characteristics of the turbine extremity regions i.e. the blade tip and endwall regions. The heat transfer and secondary flow characteristics were analyzed for different engine relevant configurations and exit Mach/Reynolds number conditions. The experiments were conducted in a linear blowdown cascade at transonic high turbulence conditions of Mexit ~ 0.85, 0.60 and 1.0, with an inlet turbulence intensity of 16% and 12% for the vane and blade cascade respectively. Transient infrared (IR) thermography technique and surface pressure measurement were used to map out the surface heat transfer coefficient and aerodynamic characteristics. The experiments were complemented with computational modeling using the commercial RANS equation solver ANSYS Fluent. The CFD results provided further insight into the local flow characteristics in order to elucidate the flow physics which govern the measured heat transfer characteristics. The results reveal that the highest heat transfer exists in regions with local flow reattachment and new-boundary layer formation. Conversely, the lowest heat transfer occurs in regions with boundary layer thickening and separation/lift-off flow. However, boundary layer separation results in additional secondary flow vortices, such as the squealer cavity vortices and endwall auxiliary vortex system, which significantly increase the stage aerodynamic losses. Furthermore, these vortices result in a low film-cooling effectiveness as was observed on a squealer tip cavity with purge flow. Finally, the importance of transonic experiments in analyzing the turbine section heat transfer and flow characteristics was underlined by the significant shock-boundary layer interactions that occur at high exit Mach number conditions. / Ph. D.

This study performed detailed measurements on and around scaled up conducting and adiabatic airfoils with and without film cooling. The conducting vane was a matched Bi airfoil, which accurately scaled the convective heat transfer and conduction through the solid, in order to produce non-dimensional surface temperatures and thermal boundary layers that were representative of an actual engine. Measurements made on all vane models included surface temperature measurements and thermal profiles above the walls. Separate measurements on non-film cooled and film cooled conducting models allowed for the individual contributions of the internal convective cooling and external film cooling to the overall cooling scheme to be quantified. Surface temperature and thermal field measurements above the wall were also performed on a film cooled adiabatic model. For the conducting model with internal cooling only, strong streamwise temperature variations were seen. The surface temperature variations were highly dependent on the local external and internal heat transfer coefficients. Spanwise temperature variations also existed, but were modest in comparison to streamwise variations. Comparing the thermal fields above the film cooled adiabatic and conducting walls allowed for the assumption that the conducting wall would not significantly affect the thermal field in the film cooling jet to be tested. Near the edge of the film cooling jet the developing thermal boundary layer had a clear effect on the overlying gas temperature, suggesting that the common assumption that the adiabatic wall temperature is the appropriate driving temperature for heat transfer to a film cooled wall was invalid. On the jet centerline thermal boundary layer effects were less influential, due to the development of a new, thin boundary layer. This suggested that the adiabatic wall temperature as driving temperature for heat transfer was a reasonable assumption on the jet centerline for most cases tested. As film cooling momentum flux ratio increase, thermal boundary layer effects became more influential on the jet centerline. Additionally, the high resolution surface temperature measurements and thermal field measurements above the wall presented in the current study represent a significant improvement in the data available for validation of computational simulations of conducting turbine airfoils. / text