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As the performance required of high pressure turbines continues to increase, there is a need to investigate many details of the flow which occur in a gas turbine stage that were previously overlooked. These include the effects of rotation and three-dimensional flow as well as unsteady effects due to the relative motion of the blade rows. In order to obtain a better understanding of the turbine flowfield a new transient facility has been commissioned in which aerodynamic and heat transfer measurements can be undertaken in a full stage turbine at engine representative conditions. The previously used technique of measuring the heat transfer rate by mounting thin film gauges on models manufactured from machineable glass ceramic was not suitable for use on the rotor blade because of the high stress levels involved. An alternative technique has been developed in which a metal turbine blade is coated with an insulating layer of enamel and thin film gauges painted on top. The developments in signal processing and calibrations which were necessary for the use of this type of thin film gauge are discussed in detail. Signal conditioning electronics have been developed which permit amplification of the thin film gauge output to a higher level within the rotating frame before transmission through a slipring. Extensive tests have been undertaken, in a purpose built spinning rig, to establish the effects of rotation on the performance and mechanical integrity of the instrumentation and associated electronics. The heat transfer measurements recorded in the rotor facility to date are presented and compared with data from a previous two-dimensional simulation of wake passing flow on the mid-height section of the same blade.

This research is concerned with a single crystal nickel-base superalloy which has been developed for application as a high pressure turbine blade material in jet aircraft engines. The microstructures and mechanical properties of superalloys, including the effects of heat-treatments, have been reviewed. The effects of heat-treatments on the γ' precipitate distributions have been investigated. During ageing at 900°C or 800°C, the precipitates adopt an irregular, rounded and highly interconnected microstructure, indicative of precipitate coalescence, whilst at higher ageing temperatures a regular cuboidal precipitate morphology is formed. The kinetics of precipitate coarsening have been investigated, and slight deviations from the power-law predicted by a number of theoretical models were observed. These deviations have been discussed in terms of a progressive transition in the dominant coarsening mechanism. Constant load creep tests were carried out, and although the tensile axis was nominally parallel to [001], the degree and direction of misorientation were found to be critical to the extent of the primary creep strain. Primary creep was shown to proceed by slip on a single (111)[112] system, until the activation of intersecting slip systems brings about the onset of the secondary creep stage. The extent of primary creep has been shown to be reduced by application of a final ageing treatment at 870°C. Precipitate shear by paired dislocations in intense slip bands occurs during high strain-rate deformation at both ambient temperature and at 750°C. Application of a final ageing treatment at 870°C was found to increase the 0.2% proof stress and to bring about the activation of an alternative mode of precipitate shear by dissociated dislocations. The 870°C ageing treatment was shown to cause slight chemical changes at the γ/γ' interfaces, and these are believed to have caused the observed changes in mechanical properties.

The growth of thrust and improved aeroengine efficiency has been gained by increased temperatures throughout the engine. This has been achieved by improved material technology and the continuous cooling of components complemented by the addition of thermal barrier coatings (TBC) to turbine and combustion chamber components. The aggressive nature of the application process of the TBC has previously made the measurement of metal surface temperature and strain exceedingly difficult on components to which it is applied. In the present study magnetron sputter-deposited thin film sensor techniques have been developed specifically for compressor and turbine applications of noble metal thermocouples and strain gauges. The deposition, patterning and evaluation of reactively sputtered aluminium oxide, type R platinum thermocouples as well as PdCr and PtW dynamic strain gauges is reported. A sputtered NiCoCrAlY coating has been developed to replace the vacuum plasma spray process currently used in the TBC system. The most favourable location for the thin film sensor is at the metal/ceramic interface of the TBC system. However, in order to protect the sensor from the aggressive TBC process, the sensor has been deposited in a novel installation between two layers of NiCoCrAlY bond coat. Several trials have been performed to fabricate this package on turbine blade material substrates. This work has demonstrated that the proposed sensor structure is feasible. However there are problems with delamination due to contamination and residual stress and with poor electrical insulation and these have limited the high temperature testing that could be performed. The novel techniques developed are already being utilised in measurement applications on components without TBCs. This work has been performed in an industrial context. The extensive project and risk management activities are reported.

Significant progress has been made towards developing an effective solution method for predicting low-speed flows through vertical-axis wind turbines. A Godunov-type finite-volume scheme has been developed for the solution of the Euler equations in two-dimensions on a multi-block mesh. The proposed algorithm features a parallel block-based adaptive mesh refinement scheme and a mesh adjustment procedure to enable straightforward meshing of irregular solid boundaries. A low-Mach-Number preconditioner is used in conjunction with a dual timestepping scheme to reduce the computational costs of simulating low-speed unsteady flows. A second-order backwards differencing time-marching scheme is used for the outer physicaltime discretization, and an explicit optimally-smoothing multi-stage time-stepping scheme with multigrid acceleration is used for the inner pseudo-time loop. Results are presented for various low-speed flows that demonstrate the suitability of the algorithms for wind turbine flows. Additional theory and discussion are also presented for extension of the schemes to the full Navier-Stokes equations.

Significant progress has been made towards developing an effective solution method for predicting low-speed flows through vertical-axis wind turbines. A Godunov-type finite-volume scheme has been developed for the solution of the Euler equations in two-dimensions on a multi-block mesh. The proposed algorithm features a parallel block-based adaptive mesh refinement scheme and a mesh adjustment procedure to enable straightforward meshing of irregular solid boundaries. A low-Mach-Number preconditioner is used in conjunction with a dual timestepping scheme to reduce the computational costs of simulating low-speed unsteady flows. A second-order backwards differencing time-marching scheme is used for the outer physicaltime discretization, and an explicit optimally-smoothing multi-stage time-stepping scheme with multigrid acceleration is used for the inner pseudo-time loop. Results are presented for various low-speed flows that demonstrate the suitability of the algorithms for wind turbine flows. Additional theory and discussion are also presented for extension of the schemes to the full Navier-Stokes equations.

During 2006 and 2007 behavioral observations surveys of raptors were conducted at 12 turbines of a 66-turbine wind farm near Port Burwell, Ontario, Canada. Mortality surveys were conducted at all turbines in the wind farm with additional search effort at the twelve turbines where behavioral monitoring was conducted. The wind farm is located along a significant autumn raptor migration corridor along Lake Erie which is in the area of the Central Flyway. Only one raptor fatality was found each year at the 12 turbines used in the study, with one additional fatality found at the other 54 turbines in the wind facility. The estimated mortality rate for Erie Shore Wind Farm ranged from 0.028 to 0.049 raptor fatalities/MW/autumn. The estimated mortality rate for Erie Shores is at the low end of mortality for North American wind facilities outside of California, and which are not located in known migratory pathways. My findings suggest that the presence of high numbers of migrant raptors passing over a wind facility site does not automatically equate to high collision mortality. Over 5,579 observations of individual raptor passes within 250m of a turbine were recorded. The majority of raptors (73%) passed outside of blade sweep height. The majority of raptors avoided entering the risk zone of operational turbines with 2.92% (n = 159) of raptors observed passing within the risk zone of blade sweep height above ground and 0-40m out from the turbine base. The majority (73%) of raptors that entered the risk zone did so under conditions when risk was reduced due to turbine blade orientation in relation to the raptors’ direction of movement or when the turbine was not operational.

Aeroacoustic emissions were identified as a primary concern in the public acceptance of wind turbines. A review of literature involving sound localization was undertaken and led to the design of two microphone arrays to identify acoustic sources. A small-scale array composed of 27 sensors was produced with the intention of improving the quality of sound measurements over those made by a single microphone in a small, closed-loop wind tunnel. A large-scale array containing 30 microphones was also implemented to allow for measurements of aeroacoustic emissions from airfoils and rotating wind turbines. To minimize cost and pursue alternative sensor technologies, microelectromechanical microphones were selected for the array sensors and assembled into the arrays on printed circuit boards. Characterization of the microphones was completed using a combination of calibration techniques, primarily in a plane wave tube. Array response to known sources was quantified by analyzing source maps with respect to source location accuracy, beamwidth, and root mean square error. Multiple sources and rotating sources were tested to assess array performance. Following validation with known sources, wind tunnel testing of a 600 watt wind turbine was performed at freestream speeds of 2.5 m/s, 3.5 m/s, 4.5 m/s, and to 5.5 m/s. Significant aeroacoustic emissions were noted from the turbine in the 4.5 m/s and 5.5 m/s cases, with an increase of up to 12 dB over background levels. Source maps from the 5.5 m/s tests revealed that the primary location of aeroacoustic emissions was near the outer radii of the rotor, but not at the tip, and generally moved radially outward with increasing frequency. The azimuthal location of the greatest sound pressure levels was typically found to be between 120º and 130º measured counterclockwise from the upward vertical, coinciding with the predicted location of greatest emissions provided by an analytical model based on dipole directivity and convective amplification. Analysis of the acoustic spectra, turbine operating characteristics, and previous literature suggested that the sound emissions emanated from the trailing edge of the blades.

State of the art aircraft afterburners employ spray bars to inject fuel and flameholders to stabilize the combustion process. Such afterburner designs significantly increase the length (and thus weight), pressure losses, and observability of the engine. This thesis presents a feasibility study of a compact prime and trigger (PAT) afterburner concept that eliminates the fuel spray bars and flameholders and, thus, eliminates the above-mentioned problems. In this concept, afterburner fuel is injected just upstream or in between the turbine stages. Downstream of the turbine stages, a low power pilot, or trigger , can be used to control the combustion process. The envisioned trigger for the PAT concept is a jet of product gas from ultra-rich hydrocarbon/air combustion that is injected through the afterburner liner. This partial oxidation (POx) gas, which consists mostly of H2, CO, and diluents, rapidly produces radicals and heat that accelerate the autoignition of the primed mixture and, thus, provide an anchor point for the afterburner combustion process. The objective of this research was to demonstrate the feasibility of the PAT concept by showing that (1) combustion of fuel injected within or upstream of turbine stages can occur only downstream of the turbine stages, and (2) the combustion zone is compact, stable and efficient. This was accomplished using two experimental facilities, a developed theoretical model, and Chemkin simulations. The first facility, termed the Afterburner Facility (AF), simulated the bulk flow temperature, velocity and O2 content through a turbojet combustor, turbine stage and afterburner. The second facility, termed the Propane Autoignition Combustor (PAC), was essentially a scaled-down, simplified version of the AF. The developed model was used to predict and interpret the AF results and to study the feasibility of the PAT concept at pressures outside the AF operating range. Finally, the Chemkin simulations were used to study the effect of several POx gas compositions on the afterburner combustion process.