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.

No description available.

L’influence de certains effets technologiques sur les performances d’une turbine n’est pas encore bien comprise. En particulier, des essais ont été réalisés par Safran Helicopter Engines sur un étage de turbine haute pression dont l’anneau de roue forme une cavité reliée à la veine au niveau de l’espace inter-grilles, dans laquelle est injecté de l’air de refroidissement. Ils ont montré une sensibilité inattendue des performances à certains paramètres géométriques. Cette thèse a pour but d’expliquer ce comportement, et d’améliorer la compréhension et la prédiction par simulation numérique de l’effet d’une telle cavité sur l’aérodynamique et l’aérothermique de la turbine. Cette problématique a été traitée à l’aide de simulations numériques RANS instationnaires, réalisées avec le code elsA. Dans un premier temps, seule une partie de la cavité a été simulée, ce qui la ramène à une simple injection d’air de refroidissement dans la veine par une fente axisymétrique. Ces calculs ont montré que l’écoulement dans la veine est profondément modifié par l’air de refroidissement. Entre autres, le tourbillon de passage au carter et l’écoulement de jeu dans le rotor sont impactés, et deviennent fortement instationnaires. Les mécanismes d’interaction entrant en jeu sont détaillés, et l’effet sur les pertes est discuté. Des calculs prenant en compte la cavité entière ont ensuite été mis en place, d’abord avec un écoulement dans la veine simplifié, puis avec l’étage de turbine complet. Ils ont permis d’identifier une structure composée de poches de gaz de veine ingéré dans la cavité et de zones d’éjection d’air de refroidissement, tournant à une vitesse inférieure à celle du rotor, et manifestement générée par une instabilité. Des structures semblables avaient déjà été identifiées dans des turbines par de nombreuses études concernant des cavités inter-disques au moyeu, mais c’est ici la première fois qu’un tel comportement est obtenu dans une cavité composée de parois fixes et débouchant au carter. L’effet de cette structure sur l’écoulement dans la veine est qualitativement identique à celui obtenu par les simulations avec seulement une partie de la cavité, mais l’intensité et la fréquence des phénomènes d’interaction entre l’air de refroidissement injecté et l’écoulement principal sont modifiés par la rotation de la structure dans la cavité. Finalement, bien que les résultats d’essai n’ont pas pu être entièrement expliqués, ces travaux ont permis d’améliorer la compréhension des phénomènes se produisant dans une telle configuration, d’identifier les défis qu’ils posent aux simulations numériques, et d’ouvrir de nouvelles pistes de recherche. / The impact of some technological effects on the performances of a turbine are not yet well understood. More specifically, tests were performed by Safran Helicopter Engines on a high pressure turbine stage featuring a cavity over the rotor shroud, connected to the main gas path in the inter-rows space. Cooling air is injected in this cavity. This experimental campaign has shown an unexpected sensitivity of the turbine performances to some geometric parameters. This thesis aims at explaining this behaviour, and at improving the understanding and the prediction through numerical simulations of the effect of such a cavity on the aerodynamic and aerothermic behaviour of the turbine. Unsteady RANS numerical simulations have been performed with the elsA code. First, simulations were set up with a small part of the cavity, which forms a simple axisymmetric slot injecting cooling air into the main gas path. These computations have shown that the flow through the stage is deeply modified by the injected cooling air. The rotor shroud passage vortex and the tip leakage flow are affected and undergo large fluctuations. The interaction mechanisms are detailed and the effect on loss generation is discussed. Then, computations modeling the full cavity were performed, beginning with a simplified annulus flow and next with the full turbine stage. They identified a flow structure made of hot annulus gas pockets ingested in the cavity and cooling air ejection zones. This structure rotates at a lower speed than the rotor, and is clearly generated by an aerodynamic instability. Similar structures had already been found in turbines by numerous studies on inter-disks cavities at the hub, but it is the first time that such a behaviour is reported in a cavity with fixed walls and located at the shroud. The effect of this structure on the flow through the annulus is qualitatively identical to that simulated with only a small part of the cavity, but the intensity and the frequency of the interaction phenomena between the cooling air and the main flow are modified because of the rotation of the cavity flow structure. Finally, even if the simulations did not manage to fully explain the experimental results, this work contributed to the improvement of the understanding of the phenomena occuring in such a configuraiton. It also identified some challenges for the modelling of these flows by numerical simulations, as well as some topics for future research.

The design parameters axial gap and stator count of highpressure turbine stages are evaluated numerically towards theirinfluence on the unsteady aerodynamic excitation of rotorblades. Of particular interest is if and how unsteadyaerodynamic considerations in the design could reduce the riskofhigh cycle fatigue (HCF) failures of the turbine rotor. A well-documented 2D/Q3D non-linear unsteady code (UNSFLO)is chosen to perform the stage flow analyses. The evaluatedresults are interpreted as aerodynamic excitation mechanisms onstream sheets neglecting 3D effects. Mesh studies andvalidations against measurements and 3D computations provideconfidence in the unsteady results. Three test cases areanalysed. First, a typical aero-engine high pressure turbinestage is studied at subsonic and transonic flow conditions,with four axial gaps (37% - 52% of cax,rotor) and two statorconfigurations (43 and 70 NGV). Operating conditions areaccording to the resonant conditions of the blades used inaccompanied experiments. Second, a subsonic high pressureturbine intended to drive the turbopump of a rocket engine isinvestigated. Four axial gap variations (10% - 29% ofcax,rotor) and three stator geometry variations are analysed toextend and generalise the findings made on the first study.Third, a transonic low pressure turbine rotor, known as theInternational Standard Configuration 11, has been modelled tocompute the unsteady flow due to blade vibration and comparedto available experimental data. Excitation mechanisms due to shock, potential waves andwakes are described and related to the work found in the openliterature. The strength of shock excitation leads to increasedpressure excitation levels by a factor 2 to 3 compared tosubsonic cases. Potential excitations are of a typical wavetype in all cases, differences in the propagation direction ofthe waves and the wave reflection pattern in the rotor passagelead to modifications in the time and space resolved unsteadypressures on the blade surface. The significant influence ofoperating conditions, axial gap and stator size on the wavepropagation is discussed on chosen cases. The wake influence onthe rotorblade unsteady pressure is small in the presentevaluations, which is explicitly demonstrated on the turbopumpturbine by a parametric study of wake and potentialexcitations. A reduction in stator size (towards R≈1)reduces the potential excitation part so that wake andpotential excitation approach in their magnitude. Potentials to reduce the risk of HCF excitation in transonicflow are the decrease of stator exit Mach number and themodification of temporal relations between shock and potentialexcitation events. A similar temporal tuning of wake excitationto shock excitation appears not efficient because of the smallwake excitation contribution. The increase of axial gap doesnot necessarily decrease the shock excitation strength neitherdoes the decrease of vane size because the shock excitation mayremain strong even behind a smaller stator. The evaluation ofthe aerodynamic excitation towards a HCF risk reduction shouldonly be done with regard to the excited mode shape, asdemonstrated with parametric studies of the mode shapeinfluence on excitability. <b>Keywords:</b>Aeroelasticity, Aerodynamics, Stator-RotorInteraction, Excitation Mechanism, Unsteady Flow Computation,Forced Response, High Cycle Fatigue, Turbomachinery,Gas-Turbine, High-Pressure Turbine, Turbopump, CFD, Design

<p>The design parameters axial gap and stator count of highpressure turbine stages are evaluated numerically towards theirinfluence on the unsteady aerodynamic excitation of rotorblades. Of particular interest is if and how unsteadyaerodynamic considerations in the design could reduce the riskofhigh cycle fatigue (HCF) failures of the turbine rotor.</p><p>A well-documented 2D/Q3D non-linear unsteady code (UNSFLO)is chosen to perform the stage flow analyses. The evaluatedresults are interpreted as aerodynamic excitation mechanisms onstream sheets neglecting 3D effects. Mesh studies andvalidations against measurements and 3D computations provideconfidence in the unsteady results. Three test cases areanalysed. First, a typical aero-engine high pressure turbinestage is studied at subsonic and transonic flow conditions,with four axial gaps (37% - 52% of cax,rotor) and two statorconfigurations (43 and 70 NGV). Operating conditions areaccording to the resonant conditions of the blades used inaccompanied experiments. Second, a subsonic high pressureturbine intended to drive the turbopump of a rocket engine isinvestigated. Four axial gap variations (10% - 29% ofcax,rotor) and three stator geometry variations are analysed toextend and generalise the findings made on the first study.Third, a transonic low pressure turbine rotor, known as theInternational Standard Configuration 11, has been modelled tocompute the unsteady flow due to blade vibration and comparedto available experimental data.</p><p>Excitation mechanisms due to shock, potential waves andwakes are described and related to the work found in the openliterature. The strength of shock excitation leads to increasedpressure excitation levels by a factor 2 to 3 compared tosubsonic cases. Potential excitations are of a typical wavetype in all cases, differences in the propagation direction ofthe waves and the wave reflection pattern in the rotor passagelead to modifications in the time and space resolved unsteadypressures on the blade surface. The significant influence ofoperating conditions, axial gap and stator size on the wavepropagation is discussed on chosen cases. The wake influence onthe rotorblade unsteady pressure is small in the presentevaluations, which is explicitly demonstrated on the turbopumpturbine by a parametric study of wake and potentialexcitations. A reduction in stator size (towards R≈1)reduces the potential excitation part so that wake andpotential excitation approach in their magnitude.</p><p>Potentials to reduce the risk of HCF excitation in transonicflow are the decrease of stator exit Mach number and themodification of temporal relations between shock and potentialexcitation events. A similar temporal tuning of wake excitationto shock excitation appears not efficient because of the smallwake excitation contribution. The increase of axial gap doesnot necessarily decrease the shock excitation strength neitherdoes the decrease of vane size because the shock excitation mayremain strong even behind a smaller stator. The evaluation ofthe aerodynamic excitation towards a HCF risk reduction shouldonly be done with regard to the excited mode shape, asdemonstrated with parametric studies of the mode shapeinfluence on excitability.</p><p><b>Keywords:</b>Aeroelasticity, Aerodynamics, Stator-RotorInteraction, Excitation Mechanism, Unsteady Flow Computation,Forced Response, High Cycle Fatigue, Turbomachinery,Gas-Turbine, High-Pressure Turbine, Turbopump, CFD, Design</p>

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.

Afin d’augmenter le rendement et la puissance spécifique des turbines à gaz, la température en entrée de la turbine haute pression a été continuellement augmentée, au point d’atteindre une valeur de l’ordre de la température de fusion des matériaux. La capacité à prédire l’écoulement (température en particulier) dans la turbine est donc un élément essentiel pour la conception des turbines à gaz, particulièrement pour celle qui ne sont pas refroidies. Toutefois, cette tâche est rendue difficile par l’extrême complexité de l’environnement dans lequel la turbine évolue (interaction avec la chambre de combustion, effets technologiques, couplage thermique fluide / solide, etc.).L’objectif de ce travail de thèse est de proposer, d’une part une stratégie de simulation numérique afin de prédire au mieux les champs aérothermiques dans une turbine haute-pression, d’autre part une méthode d’analyse permettant de quantifier l’impact des différents éléments de l’environnement sur les performances. Pour répondre à ces objectifs, des simulations instationnaires d’un étage de turbine ont été réalisées avec le code elsA, prenant en compte les effets technologiques (baignoire, refroidissement externe grâce aux évents du distributeur et aux cavités moyeu et carter du rotor qui sont alimentés par le système d’air secondaire, congés de raccordement) et les transferts thermiques conjugués. Une analyse de la production locale d’entropie a aussi été menée afin de comparer les performances aérodynamiques pour plusieurs niveaux d’approximations dans la définition de la turbine (prise en compte ou non de tel ou tel effet technologique) et de localiser l’origine de ces différences. L’analyse des résultats a montré que la hauteur de jeu et le système de refroidissement externe ont l’impact le plus significatif sur les performances aérodynamiques de la turbine. La température de paroi de la pale de rotor est de son côté fortement influencée par l’écoulement issu de la chambre de combustion, le refroidissement externe et le couplage thermique fluide / solide. Ce travail est un premier pas vers la réalisation de simulations totalement intégrées qui doivent permettre d’améliorer la précision des conceptions. / In order to increase the thermodynamic efficiency of gas turbine engines, the high-pressure turbine inlet temperature has been continually increased up to reach levels of the order of magnitude of the vanes and blades melting temperatures. The ability of predicting the flow through the turbine(especially the temperature) is a key point for the design of gas turbines, especially for the uncooled ones. However, this is challenging because of the complex environment that interacts with the turbine(hot-streak migration, technological details, fluid/solid thermal coupling . . .).The aim of this work is to develop a strategy based on CFD in order to predict aerothermal fields in a high-pressure turbine as well as an analysis allowing to quantify the impact of the environment on the turbine performances. To achieve these goals, the elsA code has been used to perform unsteady simulation of a turbine stage, taking into account technological details (squealer tip, external cooling thanks to vane trailing edge cooling and rotor hub and shroud cooling cavities, fillets) and conjugate heat transfers. An analysis of the local entropy production rate was also used to compare the performances resulting from different modeling of the turbine (taking into account or not one particular technological detail) and to localize the origin of these discrepancies. The results show that the tip height and the external cooling have the greatest impact on the turbine performances. The rotor blade temperature is mainly affected by the flow coming from the combustion chamber, the external cooling and the fluid / solid thermal coupling. This work is the first step towards the realization of integrated simulations allowing to improve the accuracy of design.

No description available.

No description available.

Ce travail porte sur l'étude du comportement sous sollicitation de fretting sirnple à haute température de superalliages monocristallins à base de nickel MC2 et CMSX-4. Il trouve son application dans le domaine aéronautique, plus précisément au niveau de la turbine haute pression des moteurs d'hélicoptère. Celle-ci a pour fonction de convertir l'énergie cinétique des gaz brûlés en un couple qui entraîne en rotation le compresseur. Elle participe ainsi directement à l'entretien du cycle de combustion du moteur ce qui fait d'elle un organe clé. Située directement en aval de la chambre de combustion, la turbine haute pression (HP) est composée d'un disque central polycristallin et d'aubages monocristallins rapportés, liés au disque par une liaison dite pied de sapin. La rotation de la turbine et la température élevée des gaz de combustion va générer sur les aubes, le disque et l'attache qui les relie，des sollicitations thermomécaniques importantes. Du fait de la force centrifuge et du défilement des aubes devant les étages fixes des distributeurs, l'attache pied de sapin est la cible d 'oscillations dynamiques à l'origine de phénomènes d'endommagement par fretting. Ce fretting,, l'interface de contact entre l'aube et le disque fait l'objet d'une attention toute particulière，ce qui a motivé la conduite de ces travaux. Après une première phase et développement et de validation d'un banc d'essai innovant qui a nécessité la mise en place d'un dispositif de chauffage par induction, un soin tout particulier est apporté à la préparation des échantillons. La nature monocristalline du matériau constitutif des aubes nécessite en effet de respecter précisément l'orientation de la microstructure par rapport aux axes de sollicitation et la surface de contact. Pour cela une mesure systématique de la désorientation des axes primaires et secondaires des barreaux bruts est réalisée. La désorientation relevée est ensuite compensée au cas par cas lors du prélèvement par électroérosion des échantillons. Le lot d'échantillons obtenu peut dès lors être considéré comme homogène en terme d'orientation, malgré le fait que les barreaux bruts présentent des désorientations différentes. [...] / The aim of this work is to study the behavior of MC2 and CMSX-4 nickel based superalloys when subjected to fretting load at high temperature. Since it drives the compressor shaft, the high pressure turbine is a key part of the helicopter engine. 1n order to increase the global reliability and efficiency of the engine, single crystal nickel based superalloys are employed for turbine blades while disk parts are made of polycrystalline materials. Each turbine blade is attached to the central disk via a special link called fir tree root. Due to high temperature and dynamic oscillations, the contact zone between blades and disk is subjected to high thermomechanical stresses. 1t causes fretting phenomena that can lead to wear and cracking damage. This work focuses on both the partial slip and gross slip regime in order to study the damage process of single crystal MC2 and CMSX-4 materials. To perform the mechanical tests, an innovative fretting device is designed to fit the specifications. The use of an induction heat system allows an accurate control of high temperatures. To be consistent with the real flying parts,，the specific orientation of the microstructure of the material with respect to the contact loading direction is taken into account. The microstructure misalignement of raw material bars is measured and compensated as the specimens are machined for extraction. Consequently the obtained set of samples is considered to be of homogeneous microstructure orientation even if their source material contains deviations in orientation. Four material states are investigated: precision grinding conventional shot-peening ultrasonic shot-peening and nitriding process. The results show that for the partial slip régime, shot peening processes are very useful for turbine blade applications. As a matter of fact, the risk for crack nucleation and extension are reduced by the introduction of residual stresses beneath the surface in spite of the high temperature. 1nvestigating the gross slip regime results show that wear of material leads to the formation of a third body and then to the formation of a thin layer called "glaze layer)) with low friction coefficient. To describe the formation process of the "glaze layer)) halted trials are performed. The results allow the drafting of a scenario in which wear debris are stuck and sintered beneath the contact.